EURO IV - VEHICLE SERVICE MANUAL

Classic Bullet EFI

Bullet EFI

Continental GT

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PREFACE

“FIRST TIME RIGHT” is a very important element for enhancing Customer Satisfaction.

Royal Enfield is committed to upgrade the skills and knowledge of technicians so that they follow scientific repair
techniques to ensure “FIRST TIME RIGHT” practices and carry out repairs accurately so that customers will enjoy
trouble free performance at all times.

This Maintenance and service manual is specifically for the following EURO IV Regulation models being currently sold
only in UK & European countries.

 BULLET EFI

 BULLET CLASSIC EFI

 CONTINENTAL GT

This Manual is intended for use primarily by a person who is well versed with basic repair technique of a motorcycle
& usage of general purpose tools and special service tools & diagnostic tools, while basic & routine service maintenance
may be in the event of not having possibility in carrying out using basic tools, required tools it is recommended that
the motorcycle may please be get inspected and serviced through an Authorized Royal Enfield Service Station.

This manual will help in guide in the basic servicing, periodical maintenance, systematic disassembly, Parts inspection
and assembling procedures of various mechanisms / systems of the motorcycle which has to be carried out in Royal
Enfield Authorised Dealership or Service Station.

While this manual is updated with latest Information and Specifications, at the time of going to print, due to continuous
improvements being done to improve performance, some of the data, illustrations etc., in this manual may differ
from the actual parts fitted in the engine.

Subsequent & continuous improvement that may be done on the motorcycles to enhance customer satisfaction, will
be uploaded also in the RMI portals & also available with Royal Enfield Authorised dealer & Service Station.

Please do feel free to write to us at [email protected], if you have any queries, clarification, suggestions or
feedback.

With warm regards

SERVICE HEAD QUARTERS

Royal Enfield, A Unit of Eicher Motors Limited,
Thiruvottiyur High Road, Thiruvottiyur, Chennai - 600 019.
E-mail: [email protected]
Website: www.royalenfield.com

Part No: 888569 / Feb. ’17

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EURO IV BIKES – VEHICLE VIEWS

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TABLE OF CONTENTS

SL.NO. DESCRIPTION PG.NO. SL.NO. DESCRIPTION PG.NO.

1. Technical Specifications ............................................ 4 7. Rear Suspension

2. Periodical Maintenance ............................................. 6 7.1 Rear Wheel ....................................................... 103

3. Special Tools Usage List ............................................. 8 7.2 Rer Sprocket / Drive Chain Adjustment ....... 111

4. Engine Removal from Frame ..................................... 9 7.3 Rear Shockers .................................................. 113

5. Vehicle Aggregagetes 7.4 Rear Mudguard / Rear Number Plate ........... 119

5.1 Cables ............................................................... 11 7.5 Swing Arm ........................................................ 126

5.2 Airfilter Paper Element .................................. 16 8. ABS ........................................................................... 133

5.3 Fuel Tank .......................................................... 23 9. EVAP ........................................................................... 167

5.4 Seat Assembly ................................................. 30 10. EMS ........................................................................... 174

5.5 Exahust Pipe & Silencer ................................. 39 11. NACS II DIAGNOSIS ..................................................... 213

6. Front Suspension 12. Electricals

6.1 Front Wheel ..................................................... 46 12.1 Battery .............................................................. 233

6.2 Front Mudguard .............................................. 54 12.2 Bulbs ................................................................. 239

6.3 Handle Bar ....................................................... 60 12.3 Electrical Components ................................... 261

6.3 Front Fork ........................................................ 70 12.4 Wiring Diagram ............................................... 277

6.4 Steering Stem .................................................. 87 13. Trouble Shooting ........................................................ 286

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SECTION 01 - TECHNICAL SPECIFICATION

TECH SPEC POINT BULLET

CLASSIC EFI BULLET EFI CONTINENTAL GT
ENGINE
Engine 4 Stroke, air cooled, single cylinder 4 Stroke, air cooled, single cyl., OHV, SI
Capacity 499 cc (Displacement) 535 cc
Bore 84 mm 87 mm
Stroke 90 mm 90 mm
Compression ratio 8.5 : 1 8.5 : 1
Max. Power @ RPM 20.3 Kw @ 5250 RPM 21.4 kw @ 5100 RPM
Max. Torque @ RPM 41.3 Nm @ 4000 RPM 44 Nm @ 4000 RPM
Air filter Element Paper Element Paper Element
Lubrication Forced Lubrication, Wet Sump Forced Lubrication, Wet Sump
Fuel Supply Electronic Fuel Injection Electronic Fuel Injection
IGNITION SYSTEM
Ignition system Digital Electronic Ignition Electronic Ignition
Spark plug gap 0.8 mm 0.8 - 0.9 mm
Spark plug WQR8DC (Bosch) WQR8DC (Bosch)
TRANSMISSION
Clutch Wet Multiplate Wet Multiplate (7 Plates)
Drive Chain links 102 pitch 101 pitch 101 Pitch
Primary drive Duplex Chain drive 3/8” pitch Duplex Chain
Gear box 5 Speed Constant Mesh Constant Mesh 5 Speed
I - 3.063 : 1 I - 3.063 : 1
II - 2.013 : 1 II - 2.013 : 1
Gear Ratios III - 1.522 : 1 III - 1.522 : 1
IV - 1.212 : 1 IV - 1.212 : 1
V - 1.000 : 1 V - 1.000 : 1
Primary Drive Ratio 2.15 : 1 2.15 : 1
Secondary Drive Chain Drive 18 Teeth (F.D. Sprocket)
Secondary ratio 2.235:1 2.12:1
ELECTRICALS
Generation Alternator Alternator
System 12V DC 12V DC
Battery 12V - 14 AH 12V - 14 AH
Head lamp 12V, 60/55 W 12V, 60/55 W, Halogen Bulb
Tail / Brake lamp 12V, 5/21 W 5/21 W
Turn signal 12V, 10W X 2 Nos. 12V, 10W X 4 Nos.
Pilot lamp 12V, 2 W X 2 Nos. / 12V, 4 W X 1 No. NA
Instrument Cluster NA Digital instrument Cluster with LCD
High beam indicator NA 12V, 0.2W (LED)
Neutral Indicator NA 12V, 1.12W
Horn 12V, 2.5 Amp (Max.) 12V, 2.5A (Dual tone-LT, HT)
Starter Motor NA 12V, 0.9 KW

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TECH SPEC POINT BULLET
CLASSIC EFI BULLET EFI CONTINENTAL GT
CHASSIS
Frame Tubular Frame Tubular steel double cradle
Fr : 90 / 90-19”-52 V 3.25 X 19” 110/90-18 M/C 56H
Tyre size
Rr : 110 / 80-18”-58 V 3.50 x 19" 130/70-18 M/C 63H
Front-Solo: 18 PSI Front- Solo:1.41 Kg/cm2 (20 PSI)
Pillion: 20 PSI Pillion:1.55 Kg/cm2 (22 PSI)
Tyre pressure
Rear-Solo: 28 PSI Rear- Solo:2.11 Kg/cm2 (30 PSI)
Pillion: 30 PSI Pillion:2.25 Kg/cm2 (32 PSI)
Fuel tank capacity 14.5 + 1 Litres 13.5 Litres***
Front: Telescopic, Hydraulic Damping Front:Telescopic, Stroke 110mm
Suspension stroke 110 mm
Rear: Swing arm with gas filled shockabsorbers Rear:Twin - Gas Charged,
with adjustable 5 step spring tension load. Stroke 80 mm
Front fork oil capacity 430 ml per leg 430 ml per leg
Front fork oil Gabriel Fork Oil 2W 35 Gabriel Fork Oil 2W 35
Hydraulic Disc Brakes Front & Rear Hydraulic Disc Brakes Front & Rear
with ABS System with ABS System
Brakes Front: 300 mm dia disc with twin Front:300 mm dia floating disc,
piston caliper twin piston floating caliper
Rear: 240 mm dia disc with single piston & Rear:240mm dia disc, single piston
floating caliper floating caliper
Brake oil grade DOT 4 or above DOT 4 or above
Brake oil capacity Front:60 ml Rear: 100 ml Front:50 ml Rear: 100 ml
Speedometer lamp 12V, 3.4 W X 1 No. NA
Turn signal /
High beam indicator 12V, 1.7 W each NA
Neutral Indicator 12V, 1.7 W X 1 No. NA
DIMENSIONS
Length 2140 mm 2060 mm
Width 800 mm 760 mm
Height 1080 mm 1070 mm
Wheel base 1360 mm 1360 mm
Saddle height 805 mm 790mm 810 mm
Ground clearance 140 mm 140 mm
WEIGHTS
Mass of motorcycle in running order 270 Kg 267 Kg
Max pay load 95 Kg 98 Kg
Max technical permissible mass 365 Kg 365 Kg
PERFORMANCE
Maximum Speed 128 kmph 137 Kmph

 Values / Dimensions mentioned above are for reference only.

 In view of continuous improvements being done on our motorcycles, the specifications are subject to change
without prior notice.

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SECTION 02 - PERIODICAL MAINTENANCE

BULLET CLASSIC EFI & BULLET EFI

The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the Intervals at which
regular inspections, adjustments, replacements and lubrications must be carried out to help maintain your motorcycle meticulously.
If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc.,
the maintenance will need to be done earlier as may be required.
Contact a nearest Royal Enfield Authorized Dealer / Service Center to carry out the periodical maintenance and for any expert advice.

S.
No. DESCRIPTION SCHEDULE
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75
R R R R R R
1 Engine Oil
Check level every 500 Kms or earlier as required
2 Engine oil filter element R R R R R R
3 Engine sump filter (oil strainer) C C C C C C
Magnetic drain plug under gear box and secondary C C C C C C
4 drain plug under crankshaft in crankcase right
5 Spark plug A A A A A R A A A A R
6 HT lead I I I I I I I I I I I
7 Fuel hose I I I I R I I I R I I
8 Fuel Pump Check for screw tightness in all services
9 Accelerator cable play A A A A A A A A A A A
10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I
11 Rubber hose, Inlet manifold / Adaptor I I I I R I I I R I I
12 Airfilter paper element C C C C R C C C R C C
13 Inlet/Exhaust valve seating (compression/vaccum test) I I
14 Cylinder head D
15 Exhaust system D
16 Clutch free play Adjust every 1000 Kms or earlier as required
17 Rear brake pedal pivot L L L L L L L L L L L
18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C
19 Battery Electrolyte level I I I I I I I I I I I
20 Earth wire eyelet (behind battery carrier) I I
Lubricate & Adjust every 1000 Kms/Clean, Lubricate &
21 Rear Wheel Drive Chain
Adjust every 3000 Kms or earlier as required
22 Front Fork oil R R R
23 Rear brake play Adjust every 1000 Kms or earlier as required
24 Rear brake cams L L L L L
25 Steering ball races play I A L A L A L A R A L
26 Spokes tightness / Wheel rim run out front & rear I I I I I I
27 Pivot-Side Stand, Center Stand, Pillion Foot Rest L L L L L L L L L L L
28 Tyre wear pattern (Front & Rear) I I I I I I I I I I I
29 Hand levers pivot Lubricate every 1000 Kms or earlier as required
30 Front Disc Brake Oil level check I I I I I R I I I I R
31 Evaporative Emission Equipment rubber hoses I I I I R I I I R I I
A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace
NOTE :
For maintenance after 30,000 Kms, (18,750 miles) please repeat the same frequency levels specified above, in consultation with a
Royal Enfield Authorized Dealer.

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CONTINENTAL GT
The Periodical maintenance schedule detailed below is based upon average riding conditions and indicates the Intervals at which
regular inspections, adjustments, replacements and lubrications must be carried out to help maintain your motorcycle meticulously.
If in case the motorcycle is used frequently in very dusty environment / severe climatic conditions / Poor Roads / stagnant water etc.,
the maintenance will need to be done earlier as may be required.
Contact a nearest Royal Enfield Authorized Dealer / Service Center to carry out the periodical maintenance and for any expert advice.

S.
No. DESCRIPTION SCHEDULE
Kms (x 1000) 0.5 3 6 9 12 15 18 21 24 27 30
Miles (x 1000) 0.3 2 3.75 6 7.5 9.5 11.25 13 15 17 18.75
R R R R R R
1 Engine Oil
Check level every 500 Kms or earlier as required
2 Engine oil filter R R R R R R
3 Engine sump filter C C C C C C
4 Magnetic drain plug under gear box on crankcase right C C C C C C
5 Spark plug C&A C&A C&A C&A C&A R C&A C&A C&A C&A R
6 HT lead I I I I I I I I I I I
7 Fuel hose I I I I R I I I R I I
8 Fuel Pump Check for screw tightness in all services
9 Accelerator cable play A A A A A A A A A A A
10 Rubber hose, Air filter to Throttle body I I I I R I I I R I I
11 Rubber hose, Inlet manifold I I I I R I I I R I I
12 Airfilter element C C C C R C C C R C C
13 Inlet / Exhaust valve seating I
14 Cylinder head D
15 Exhaust pipe D
16 Clutch free play Adjust every 1000 Kms (600 Miles) or earlier as required
17 Rear brake pedal pivot L L L L L L L L L L L
18 Battery terminals (apply petroleum jelly) C C C C C C C C C C C
19 Battery Electrolyte level I I I I I I I I I I I
20 Earth wire eyelet contact I I
Adjust every 1000 Kms (600 Miles) or earlier as required
21 Rear Chain
Lubricate every 3000 Kms (1800 Miles) or earlier as required
22 Fork oil R R
23 Steering ball races A L A L A
24 Spokes tightness I I I I I I
25 Wheel rim run out I I I I I
26 Tyre wear I I I I I I I I I I
27 Hand levers & Kick starter pivot Lubricate every 1000 Kms or earlier as required
28 Brake Oil level check / Replacement I I I I I I I R I I I
29 Pivot-Side Stand L L L L L L L L L L L
30 Center Stand pivot L L L L L L L L L L L
31 Pillion Foot rest pivot L L L L L L L L L L L
32 Swing arm bearings L L
31 Evaporative Emission Equipment rubber hoses I I I I R I I I R I I
A : Adjust C : Clean D : De-carbonise I : Inspect L : Lubricate R : Replace
NOTE :
For maintenance after 30,000 Kms, (18,750 miles) please repeat the same frequency levels specified above, in consultation with a
Royal Enfield Authorized Dealer.

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SECTION 03 - SPECIAL TOOLS USAGE LIST

PART NO. DESCRIPTION PHOTOS APPLICATION

ST-25834-2 Front fork Dismantling tool To hold pipe seat of front fork while
dismantling & tightening of front fork
main tube with bottom case (fork end
assy.).

ST-25114-4 Extractor for fork oil seal To remove oil seal in front fork bottom
case.

ST-25113-4 Mandrel for oil seal Fitment of oil seal into front fork
bottom case.

ST-25112-4 Expander for front fork Oil Expanding the oil seal lip while
seal inserting main tube into bottom case
of front fork

ST-25110-3 Gauge plate for tightening Alignment of Swing Arm while

chain stay mounting tightening into chassis.

ST-25244-4 Special spanner adjuster To adjust gas filled shockabsorber

spring load.

ST-25833-4 Front Fork Tool 1/2 SD To Loosen and tightening of front fork
assembly from the head lamp casing.

ST-26461-2 Front Fork Assembling & To hold pipe seat of front fork while
Dismantling Tool dismantling & tightening of front fork
main tube with bottom tube (fork end).

ST-26485-3 Front Fork Oil Seal Driver Fitment of slide bush and fork oil seal
(Dia 41mm) into front fork bottom case.

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SECTION 04 - ENGINE REMOVAL FROM FRAME

Bullet Classic EFI / Bullet EFI / Continental GT

 Disconnect alternator leads.
 Disconnect the spark plug suppressor cap.
 Disconnect the fuel pipe.
 Remove throttle body along with throttle cable.
 Remove the air filter assy.
 Remove the exhaust pipe and silencer.
 Disconnect the engine steady bolt.
 Remove the rear chain.
 Remove the LH Foot rest.
 Support the engine on a suitable box or wooden block.
 Remove the center stand and the stand stop.
 Remove the front engine plates and the small bolt fixing the stand spring bracket.
 Remove the stud securing the rear engine plate to the frame Slide out the engine.

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 SECTION 05 - VEHICLE AGGREGATES

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SECTION 5.1 CABLES

EXPLODED VIEWS
BULLET CLASSIC EFI / BULLET EFI / CONTINENTAL GT

2 3

S. NO. DESCRIPTION QTY.

1 Throttle Cable Assembly (Twin Cable) 1

2 BI Starter Cable 1

3 Clutch Cable Assembly 1

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.1 Clutch Cable
Assembly
Bullet Classic EFI/
Bullet EFI/
Continental GT
Dismantling
 Slacken the adjuster at
the clutch cover end and
disconnect the cable
from the lever.
 Gently pull out part of
the clutch cable from the
cover.
 Remove the clutch cable
from the clutch lever at
handle bar end.

5.1 Throttle Cable

Assembly (Twin
Cable)
Bullet Classic EFI/
Bullet EFI/
Continental GT
Dismantling
 Slacken the adjusters at
the throttle body end for
both cables.
 Gently remove the
Throttle cable assembly.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.1 Bi Starter Cable
Bullet Classic EFI/
Bullet EFI/
Continental GT
Dismantling
 Slacken the adjuster at
the Bi starter cable end
and disconnect the
cable from the lever.
 Gently pull out the part
of Bi starter cable.
 Remove the Bi starter
cable from the clutch
lever at handle bar end.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.1 Clutch Cable
Assembly
Bullet Classic EFI/
Bullet EFI/
Continental GT
Assembling
 Locate the clutch cable in
clutch lever at handle bar
end.
 Locate part of clutch
cable in the cover.
 Slacken the adjuster at
the clutch cover end and
Connect the cable in the
lever.

5.1 Throttle Cable

Assembly (Twin
Cable)
Bullet Classic EFI/
Bullet EFI/
Continental GT
Assembling
 Locate the Throttle
cable assembly.
 Slacken the adjusters at
the throttle body end for
both cables.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.1 Bi Starter Cable
Bullet Classic EFI/
Bullet EFI/
Continental GT
Assembling

 Locate the Bi starter

cable in the clutch lever at
handle bar end.
 Locate the part of Bi
starter cable.
 Slacken the adjuster at
the Bi starter cable end
and Connect the cable in
the lever.

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SECTION 5.2 - AIR FILTER PAPER ELEMENT

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI

11

16

12
1 13
14
11 15
7
56
67
5

3
18

19

20
4

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Air Filter Box Assembly with sticker 1 11 Inlet Bellow 1

2 Air filter element 500cc 1 12 Clip Hose - Inlet Bellow 1
3 Cover Filter element 1 13 Hexagon Socket Head Cap screw-M5X.8X20 2
4 Hex Nylock Nut M8X9.5 1 14 TA Sensor 1
5 Hex Screw M6 X 14 2 15 Gasket - Air Temp Sensor 1
6 Lock Washer M6 3 16 Rubber Tube - Air Filter 1
7 Plain Washer M6 1 17 Beading Box Cover 1
8 Plain Washer M6 1 18 Beading Cover Air Filter 1
9 Hex Nut M6 X 1 X 7 1 19 Cover Assembly - Air (Plastic) 1
10 Hex.Bolt M6 X 1 X 12 1 20 Washer - Cover M10 1

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CONTINENTAL GT

A1
1 5

2
11
3

10
9

7
8 6
8

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Air Filter Box 1 8 Pan Head Screw M5 X 12 4

2 Clamp 1 9 Inlet Cover 1

3 Pipe Outlet 1 10 Seal 1

4 TA Sensor 1 11 Element Air Filter 1

5 Hex Socket Head Cap Screw M5 X 16 2

6 Drain Pipe 1

7 Clip 1

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.2 Air Filter Element
Bullet Classic EFI/
Bullet EFI
CAUTION:
 Unlock and open the
Filter box RH. Ensure the pillion footrest is
in extended position to
avoid damage to filter box lid

 Loosen hex Nylock nut

Hex Nyloc Nut M8

 Gently pull out the cover

assembly.

 Remove cover filter

element.

 Remove the Air filter

Element.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.2 Air Filter Element
Continental GT
 Loosen and remove the Pan Head Screw M5 X 12
pan head screw in side
panel RH bottom. Screw Driver

 Remove the side panel Pan Head Screw M5 X 1

from the frame.
Screw Driver
 Remove the 4 pan head
screws on the airfilter
cover.

 Remove airfilter element

NOTE:
from the housing.
Remove rubber seal from
the cover.

CAUTION:
Ensure Purge valve is
placed safely to prevent
from damage.

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INSPECTION
 Inspect air filter element carefully for any deformation, damages, heavily clogged with dirt, soggy condition, and
/ or foreign particles embedded in the element. Replace if any of these conditions are observed.
 Inspect rubber seals, hoses, for cuts, cracks, damages. Replace seals and rubber parts whenever the induction
system is serviced.

FOR CONTINENTAL GT MODELS

 Inspect air filter housing and cover forany damages, cracks etc and replace entire assembly if damaged.

CLEANING
 Gently Tap filter element with minimum force to dislodge heavy / embedded dust particles.
 Using low pressure compressed air :
- blow air from INSIDE to OUTSIDE for Bullet EFI, Bullet Classic EFI Models.
- blow air from OUTSIDE to INSIDE for Continental GT Models.
to remove the fine dust particles. DO NOT WASH THE ELEMENT IN WATER, GASOLINE OR ANY SOLVENTS.
 Clean Airfilter element every 3,000 Kms OR more frequently if motorcycle is used in dusty / Off road conditions.
 Clean the airfilter housing internals, retainer plate etc, with a soft damp cloth to remove the dust.

REPLACE
 All ‘O’ rings, rubber beadings, seals, gaskets, rubber parts etc, whenever the airfilter assembly is serviced.
 Airfilter element evedry 12,000 Kms (7,500 Miles) or earlier if motorcycle isused in dusty / Off road conditions.

CAUTION :
Do not wash filter element using water, gasoline or any solvents as it will damage the paper element.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.2 Air Filter Element
Bullet Classic EFI/
Bullet EFI
CAUTION:
 Locate the Air filter
element inside filter box Ensure the pillion footrest
RH. is in extended position to
avoid damage to filter box
lid.
 Locate Cover filter
element over filter
element.

 Ensure rubber ring is

located in plastic cover
assembly.

 Locate Plastic cover

assembly over air filter
element in filter box RH.

 Position washer on the

mounting stud.

 Locate nyloc nut on stud Hex Nyloc Nut M8

and tighten sufficiently
till it is completely resting
on the washer and
resistance to tighten
further is felt.

 Ensure beading is
correctly located on the
filter box lid.

 Close filter box lid and

lock in place.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.2 Air Filter Element
Continental GT
 Locate Filter inside air
filter box.

 Ensure rubber ring is

correctly seated in the
cover air filter.

 Ensure cover air filter is

located properly on the Pan Head Screw M5 X 12
filter box and the cover Allen Key 4mm
is correctly located at the
mounting peg in the
housing.

 Install the 4 pan head

screws on the cover and
tighten evenly.

Pan Head Screw M5 X 12

 Ensure the rubber
grommets are in place in Allen Key 4mm
the side panel RH.
Locate side panel RH in
the frame, ensuing the
pegs in the frame are
seated in the grommets.

 Tighten the RH side

panel at the bottom
using pan head screw.

22 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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SECTION 5.3 - FUEL TANK ASSEMBLY

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI

2 3

1 4

17

17 15
16

14 18

11
13 11 20
11 12 19
11 11 12
12
12
10 12 10 10
10
10

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Fuel Tank With Sticker - Black 1 11 Washer 5

2 Cap-Fuel Tank 1 12 Washer 5
3 Thigh Pad R H 1 13 Clamp Plate - Fuel Pump 1
4 Flanged Hex Bolt M6X1X27 2 14 Fuel Pump 1
5 Washer-Tank 2 15 O Ring 1
6 Sleeve-Tank Mtg Rear 2 16 Low Fuel Sensor 1
7 Rear Damper-Tank 2 17 Front Damper-Tank 2
8 Thigh Pad L H 1 18 Quick Connector 1
9 PA Tube Assembly 1 19 Fuel Hose (Pa Tube) 1
10 Hex Socket Button Head Cap Screw M6X12 5 20 Cap,Injector 1

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CONTINENTAL GT

1 2

3
4
5 4
3 5

17 6

16 7 18
14
15 15

8
14

9
12
10 20
10 11 10
11 13 11 19
13 13
10 10
11
13

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Cap-Fuel Tank 1 11 Washer 5

2 Fuel Tank Assy With Sticker (Red) 1 12 Fuel Hose Assembly 1
3 Front Damper-Tank 2 13 Hex Socket Head Cap Screw M6 X 16 5
4 Flanged Hex Bolt M6 X 1 X 27 2 14 Hex Screw M6 X 12 4
5 Bush - Fuel Tank 2 15 Punched Washer-Fuel Gauge Mtg 4
6 Rear Damper-Tank 2 16 Fuel Gauge Unit 1
7 O Ring 1 17 O’ Ring-Fuel Gauge 1
8 Fuel Pump 1 18 Quick Connector 1
9 Clamp Plate - Fuel Pump 1 19 Fuel Hose (PA Tube) 1
10 Washer 5 20 Cap, Injector 1

24 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.3 Fuel tank -
Dismantling
Bullet Classic EFI/
Bullet EFI CAUTION:
Drain the fuel completely
 Remove Seat Assembly. from the fuel tank.
 Disconnect fuel hose
from the Fuel tank. CAUTION:
 Remove 2 Hex bolts from Ensure Ignition switch and
the rear end of fuel tank Kill switch is in OFF Position
along with washers,seals before disconnecting hose
and rear dampers. from fuel tank or before
draining the fuel.
 Ensure the handle bar is
held at straight ahead
Hex Flange Bolt M6
position.
Socket Spanner 10 mm
 Place a piece of cloth
between handle bar
clamp bolt and fuel tank.
 Gently lift up fuel tank at
the rear end to:
- Disconnect low fuel
sensor coupler. CAUTION:
- Disconnect EVAP Do not lift tank too high to
hose from the Fuel
- Prevent accidental
tank.
damage to the front
 Slide fuel tank towards end of the fuel tank.
rear to release front
- Prevent damage to
locking clamp from the
low fuel sensor
rubber supports in
coupler
frame.
- Prevent damage to
 Remove fuel tank from
EVAP hose
frame carefully.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.3 Fuel tank -
Dismantling
Continental GT
CAUTION:
 Remove Seat Assembly.
Drain the fuel completely
 Disconnect fuel hose from the fuel tank.
from the Fuel tank by
removing the quick CAUTION:
connector from the fuel Ensure Ignition switch and
pump end Kill switch is in OFF Position
before disconnecting hose
 Remove 2 Hex bolts from from fuel tank or before
the rear end of fuel tank. draining the fuel.
 Ensure the handle bar is
held at straight ahead Hex Flange Bolt M6
position. Socket Spanner 10 mm
 Place a piece of cloth at
the front end of the fuel
tank to prevent damage
while lifting and
removing tank.
 Gently lift up fuel tank at
the rear end to:
CAUTION:
Do not lift tank too high to
- Disconnect low fuel
sensor coupler. - Prevent accidental
damage to the front
- Disconnect EVAP end of the fuel tank.
hose from the Fuel
- Prevent damage to
tank.
low fuel sensor
 Slide fuel tank onwards coupler.
rear to release front - Prevent damage to
locking clamp from the EVAP hose.
rubber supports in
frame. Remove tank
from frame carefully.

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INSPECTION
 Carefully inspect fuel hose and vent hose for damage, cuts, cracks or general deterioration. Replace if necessary.

WARNING
 Gasoline is extremely flammable and highly explosive, which could result in serious injury.
 Do not smoke or allow open flame or sparks in the vicinity.
 Store the fuel carefully to avoid spillage.

TORQUE CHART

Torque Range
Aggregate Component Fastener
NM Kg-M

Fuel Tank Fuel tank Mounting Flanged hex bolt M6 * 30 5 0.5

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.3 Fuel tank -
Assembly
Bullet Classic EFI/ Place a piece of cloth on the
Bullet EFI top, front portion of the
Ensure the handle bar is fuel tank to avoid damage
due to touching of the
held at straight ahead
handle bar clamp on fuel
position.
tank.
 Position fuel tank on
frame such that the front
mounting locate on the
rubber supports in the
frame.
 Gently lift up fuel tank at
the end to:
- Connect low fuel
sensor coupler wire.
- Connect EVAP hose
to the Fuel tank.
 Connect fuel hose to the
fuel tank.
 Ensure the two dampers
and mounting sleeves
are properly located in
the mounting slots.
 Ensure the mounting
are aligned and
assemble 2 hex bolts
with large washers.
 Tighten the two bolts
evenly.
Hex Flange Bolt M6
 Assemble Seat.
Socket Spanner 10 mm
 Fill fuel in the tank.
Torque 5 Nm

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.3 Fuel tank -
Assembly
Continental GT
 Locate over flow tube
carefully into the Fuel
tank.

 Install the fuel tank

towards front to mount
into front locking clamp
into the frame. Hex Flange Bolt M6

 Place a piece of cloth Socket Spanner 10 mm

between handle bar
clamp bolt and fuel tank.

 Gently lift up fuel tank at

the end and

- Connect low fuel

sensor coupler wire.
Hex Flange Bolt M6
- Connect EVAP hose
Socket Spanner 10 mm
into the Fuel tank.
Torque 5 Nm
- Connect fuel hose
into the Fuel tank.

 Install 2 Hex bolts at the

rear end of fuel tank
along with washers,seals
and rear dampers.

 Assemble Seat.

 Fill fuel sufficiently.

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SECTION 5.4 - SEAT ASSEMBLY

EXPLODED VIEWS
BULLET EFI

2 3

4
4
2

6 6 5
10 5

7 7

9
8 9 8

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Complete Seat Assy 1 8 Stud M8 2

2 Flanged Hex. Bolt M 6 X 20 4 9 Plain Washer M8 4

3 Pillion Handle 1 10 Rubber Support Seat Front 1

4 Hex Nut With Nylon Insert, M6 4

5 Flanged Hex. Bolt M8 X 20 2

6 Hex Nut With Nylon Insert, M8 2

7 Flanged Hex Nut M8 X 7.7 X 8 2

30 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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BULLET CLASSIC EFI

14

2
3
16
4 17
12
4 15
13 6 18
4
5
11
7 21
22 20
8
4
4
9 10 9
10 19
4 12
23 16
22 17 20

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Split Seat Assy-Rider 1 12 Bush - Seat Spring 4

2 Silent Block Bracket Assy 1 13 Spring 2
3 Silent Block Seat 1 14 Split Seat Assy. Pillion 1
4 Hex. Nut with Nylock insert, M8 X 9.5 8 15 Sub Frame - Black 1
5 Seat Hinge Mounting Assembly 1 16 Flanged Hex Bolt M6 X 1 X 35 2
6 Spring Washer M8 4 17 Flanged Hex Bolt M6 X 1 X 27 2
Spring Washer M8 - Special 4 18 Flanged Hex Bolt M8 X 170 1
7 Flanged Hex. Bolt M8 X 60 1 19 Hex. Nut With Nylon Insert M8 X 9.5 1
8 Stud - Seat Mounting 1 20 Plain Washer 2
9 Hexagonal Bolt M8 X 45 2 Spring Washer 2
Domed Cap Bolt M8 X 45 (chrome) 2 21 Flanged Hex Bolt M8 X 1.25 X 16 2
10 Washer (Classic Models) 2 22 Hexagonal Nut M6 X 1 X 7 2
Plain Washer (Chrome) 2 23 Pillion Handle for Rear Seat - Black 1
11 Spring Bush 2

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CONTINENTAL GT

4 4
5 6

5 6
1

2 3
2

3
3

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Single Seat Assembly with Cowl - Red 1 5 Rubber Support-Middle 2

2 Plain Washer 3 6 Rubber Support-Front 2

3 Cross Recessed Pan Head Screw M6X14 3

4 Rubber Support-Rear 2

32 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.4 Seat - Dismantling
Bullet Classic EFI
Rider Seat Removal
Hex Nut with Nyloc
 Loosen hex bolt at the Insert M8
front end of the seat.
Socket Spanner 13 mm

 Remove the seat spring Hex Flange Bolt M8

mounting bolts on LH &
RH side. Socket Spanner 13 mm

 Gently remove the rider

seat from the frame.

Rear Seat Removal

 Hold nut and remove Flange Hex Bolt M8
long mounting bolt from
the sub frame. Socket Spanner 13 mm

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.4 Seat - Dismantling
Bullet Classic EFI
Rider Seat Removal
 Remove Rear shockers Domed Hex Nut M8
mounting Domed hex
nut from LH & RH side Double end ring spanner
and loosen the bolt. 17 mm

 Loosen the 2 hex bolt Flange hex Bolt M8

under the rear seat to
remove seat from Sub Socket Spanner 13 mm
frame.

Bullet EFI
 Remove front Hex nut Hex Flange Bolt M8
mounted on LH & RH side
of the seats. Socket Spanner 13 mm

 Remove rear hex bolt on Hex Flange Bolt M8

LH & RH side of the seats.
Gently lift the seat from Socket Spanner 13 mm
the rear end.

34 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.4 Seat -Dismantling
Continental GT
 Unlock & Remove Side
panel LH.

 Gently pull seat latch to

release seat.

SEAT LATCH

 Remove the seat

assembly.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.4 Seat - Assembling
Bullet Classic EFI
Rider Seat Assembly
 Position the rider seat on Hex Nut with Nyloc
the frame. Insert M8
Socket Spanner 13 mm

 Tighten hex bolt at the

front end of the seat. Hex Flange Bolt M8
Socket Spanner 13 mm

CAUTION:
Please take care not to
damage the fuel tank
while assy

 Tighten the seat spring

mounting bolts on LH &
RH side.

Rear Seat Assembly

 Tighten the 2 hex bolt Flange Hex Bolt M8
under the rear seat to
assemble seat into Sub Socket Spanner 13 mm
frame.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.4 Seat - Assembling
Bullet Classic EFI
Rider Seat Assembly
 Locate nut and tighten Flange hex Bolt M8
long mounting bolt into Socket Spanner 13 mm
the sub frame.

 Tighten Rear shockers

Flange Hex Nut M8
mounting Domed hex
nut & Bolt from LH & RH Double end ring spanner
side. 17 mm

Bullet EFI
 Locate the seat in to Hex Flange Bolt M8
front end tighten rear
hex bolt on LH & RH side Socket Spanner 13 mm
of the seats.

 Remove front Hex nut Hex Flange Bolt M8

mounted on LH & RH side
of the seats. Socket Spanner 13 mm

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.4 Seat -Assembling
Continental GT
 Locate front end of the
seat tab in the bracket in
the frame. Ensure the
lock pin is position on
the center of the seat
latch.

 Gently press the seat

rear end to lock the seat.

 Locate the Side panel LH

and lock in the seat.

38 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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SECTION 5.5 - EXHAUST PIPE & SILENCER

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI, CONTINENTAL GT
Bullet & Classic EFI
Continental GT
1
1
1
1
14

14 2 13
3
3 3

13
6
4
3
5 3
12
3 12
11 3
3 11
5
10 10 6
3
16
8 4 3
4 15
17 9
4
4
4 4
9

7 7

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Flanged Hex. Nut M8 X 1.25 2 9 Bracket -Silencer Mounting /Bracket Silencer 1

2 Exhaust Pipe -Guard 1 10 Gasket - Exhaust pipe & Silencer 1
3 Philips Pan Head Screw M6 X 6 5 11 Hex. Nut M6 1
4 Flanged Hex. Bolt M8 X 20 4 12 Clamp -Silencer 1
Flanged Hex. Bolt M8 X 20 2 13 Exhaust Pipe Assy. 1
Flanged Hex. Bolt M8 X 20 3 14 Exhaust Gasket (Copper) 1
5 Flanged Hex. Bolt M6 X 35 1 15 Hex. Nut with Nylon Insert, M8 1
6 Combined Heat Shield/Silencer Guard 1 16 Flange Hex. Bolt M10 X 1.5 X 35 1
7 Silencer CAT Assy. 1 17 Hex. Screw M8 X 16 1
8 Bracket front silencer 1

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.5 Exhaust System
Bullet Classic EFI/
Bullet EFI
 Disconnect HEGO sensor
connector from the
exhaust pipe by loosen-
ing the nut.

 Remove the center Hex Flange Bolt M8

silencer bracket mount-
ing screw with plain Socket Spanner 10 mm
washer.
 Remove the rear mount-
ing nut at the pillion foot
rest end mounted on
silencer.

 Remove the flange hex

Hex Flange Bolt M8
nuts from cylinder head.
Socket Spanner 10 mm

Flange Hex Nut M8

Socket Spanner 10 mm

40 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.5 Exhaust System
Continental GT
 Disconnect HEGO
sensor connector from
the exhaust pipe.

 Remove silencer
mounting bolt & nut Hex Flange Bolt M8
from the frame.
Socket Spanner 10 mm

 Remove the 2 Hex flange NOTE :

nuts holding exhaust
pipe to cylinder head. Ensure the copper gasket is
removed from the cylinder
head / exhaust pipe.

 Gently remove the Flange Hex Nut M8

silencer assembly with
Socket Spanner 10 mm
Exhaust pipe.

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INSPECTION
 Inspect Silencer and Exhaust assembles for any deep scoring / damages / dents as it might cause damage to the
internals and the catalytic converters.
 Inspect silencer and exhaust pipe joint for any signs of exhaust gas leakage.

CAUTION :
 Do not clean the silencer and exhaust internals with any solvents, gasoline etc as it will damage the catalytic
converters.

REPLACE
 Gasket between the silencer and exhaust pipe joint whenever the silencer / exhaust pipe are dismantled.
 Copper gasket between exhaust pipe and cylinder head whenever exhaust pipe is dismantled from cylinder
head.
 Copper gasket in HEGO sensor whenever exhaust pipe / hego sensor is dismantled.

42 ROYAL ENFIELD VEHICLE SERVICE MANUAL - EURO IV

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.5 Exhaust System-
Assembling
Bullet Classic EFI/
Bullet EFI
 Locate gasket on
Exhaust pipe.

 Position exhaust pipe

on the cylinder head
assembly.

Hex Flange Bolt M8

 Tighten two flange hex Socket Spanner 10 mm
nuts on exhaust pipe
into cylinder head. Torque 25 Nm

 Tighten the rear Mount-

ing nut at the pillion foot Hex Flange Bolt M8
rest end. Socket Spanner 10 mm
Torque 25 Nm

 Tighten the center Hex Flange Bolt M8

silencer bracket mount-
ing screw with plain Socket Spanner 10 mm
washer. Torque 25 Nm

 Connect HEGO sensor

connector to the exhaust
pipe.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
5.5 Exhaust System-
Assembling
Continental GT
 Locate gasket on
exhaust pipe.

 Position exhaust pipe

on the cylinder head
assembly.

 Tighten two flange hex

nuts on exhaust pipe Hex Flange Bolt M8
into cylinder head. Socket Spanner 10 mm
Torque 25 Nm

 Tighten the rear

Mounting nut at the Hex Flange Bolt M8
pillion foot rest end. Socket Spanner 10 mm
Torque 25 Nm

 Connect HEGO sensor

connector from the
exhaust pipe.

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SECTION 06 - FRONT SUSPENSION

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SECTION 6.1 - FRONT WHEEL

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI

11
12

13
14
15
16
18 19 20
7 17
8
9 10
8
7
6
5
4

3
2

4
1

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Hex Socket Button Head Screw M6*1.0 4 12 Spokes Front 40

2 Toner Front Wheel 1 13 90/90 - 19 52 V Front Tyre Import 1
3 Spindle 1 14 Tube(Tyre) 3.25X19 1
4 Socket Button Head Cap Screw 6 15 Wheel Rim (1.85 X 19'’ -1.5 Thk) 1
5 Disc Front 1 16 Rim Tape 1
6 Spacer, Disc Side 1 17 Spacer Speedodrive 1
7 Grease Seal, 25 X 40 X 7 2 18 Speedo DrIve Assy Disc Brake 1
8 Wheel Bearing 6203 (17 X 40 X 12 ) 2 19 Plain Washer,M16 1
9 Spacer Assy 1 20 Hex U Nut M16 X 1.5 1
10 Front Hub 1
11 Brass Nipples 40

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CONTINENTAL GT

13 14

15

12 16 18
17

11
8
6 10

8 9
7
5
4
3
1 2

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Hex U Nut M16 X 1.5 1 12 Nipple 3.6 mm 36

2 Washer 1 13 Tyre-Front 100/90-18" 1
3 Spacer Disc Side 1 14 Tube -Front 100/90-18" 1
4 Hex Flange Bolt M8 X 25 6 15 Rim Front Aluminium(2.5X18") 1
5 Toner-Front Wheel 1 16 Rim Tape 1
6 Front Disc 1 17 Spindle-Front Wheel 1
7 Grease Seal,25 X 40 X 7 1 18 Wheel Speed Sensor Assy 1
8 Deep Groove Ball Bearing 6203 (17X40X12) 2
9 Bearing Spacer Assy 1
10 Hub-Front 1
11 Spokes Front 36

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.1 Front Wheel
Dismantling
Bullet Classic EFI/
Bullet EFI /
Continental GT
 Place the motorcycle on
its center stand on a firm
and flat surface.
 Provide a suitable
support below the front
end of the engine such
that the front wheel is
about 4 inches (10 cms)
above the ground.
 Disconnect speedo
cable at speedo drive.
 Disconnect wheel speed
sensor coupler near
head lamp housing.

 Loosen the pinch bolt on Hex Bolt M8, Hex Nut M8

the right side fork end.
Ring Spanner 13 mm
 Hold the axle on the right Double end Ring Spanner
side and loosen the axle 13 mm
nut on the left side.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.1 Front Wheel
Dismantling
Bullet Classic EFI/
Bullet EFI /
Continental GT
 Remove the axle nut and
Hex Socket Screw M8
washer.
Allen Key 6mm
Torque 25 Nm (2.5 Kg-m)

 Tap the axle out gently

from the left side and Hex Nut M16
remove completely from Double end Spanner–
the right side. 24mm

 Slide out the wheel from

the fork legs. CAUTION:
Do not depress the front
brake lever when wheel is
 Remove the speedo removed as this will result in
drive after removing the brake pads coming too
wheel from the fork legs. far out of the brake caliper.

NOTE:
 Remove the wheel
speed sensor and spacer Place a 4 mm thick wooden
after removing wheel piece or cardboard sheet
between the brake pads to
from the fork legs.
avoid pads activation in the
event the front brake lever
is Accidently depressed.

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INSPECTION
 Inspect tyres for any side wall crack stone hits, bulge, proper seating in rim.
 Tyres button to be above the tyre wear indicator mark on the side walls.
 Inspect spokes for any loosening / breakage.
 Inspect hub or any damage.
 Inspect Toner ring for any damage.
 Axle & nut for thread damage.
 Inspect wheel rim for run out / “jump” it should not exceed 2 mm.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.1 Front Wheel
Assembling
Bullet Classic EFI/
Bullet EFI /
Continental GT

 Remove the wooden

piece / card board sheet
placed between the
brake pads.

 Locate spacer & speedo

drive on the right side in
the hub.

 Locate stepped spacer

in the left side (disc side)
of the hub with its larger
face outside.

 Locate front wheel

between the fork ends
duly ensuring the
spacers and the speedo
drive do not fall off and
the brake disc is
correctly positioned
between the brake
pads.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.1 Front Wheel
Assembling
Bullet Classic EFI/
Bullet EFI /

 Ensure the peg in the

Speedo drive is correctly
positioned in the slot in
the right side fork end.

Continental GT
 Position wheel speed
sensor such that the
wire coupler can be
connected and the wire
is not stretched.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.1 Front Wheel
Assembling
Bullet Classic EFI/
Hex nut M16
Bullet EFI
Double end spanner 17mm
 Ensure all the mounting
Torque – 70 Nm
bolts are aligned.
NOTE:
Insert axle through the right
side fork end and gently tap it
 Locate washer and nut in fully.
on the left side.
 Hold the axle from the
right side and tighten
nut on left side.
 Hold the pinch bolt and
tighten the nylock nut
on the right side fork
end. (Only Bullet Classic
EFI / Bullet EFI)

 Tighten hex socket

screw on fork end RH. Torque 25Nm
(Only for Continental
GT)
 Rotate the wheel and
check for smooth
rotation.
 Connect the speedo
cable to speedo drive
and check for proper
working of speedo
meter.
 Depress brake lever 2 or
3 times to check front
brake efficiency.

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SECTION 6.2 - FRONT MUDGUARD

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI
LH side 15
14
6 2
13
5 7
6 12
8
7
3

9 1
10
5

9
6 7
10 2
8
8
7
6
2 4

8
11 7
6

10
2 10

9
10
8 9
7 6 RH side

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Front Mudguard-Black 1 10 Spring Washer 6

2 Mudguard Stay Front Black Mod 4 11 Cable Guide 1

3 Mudguard Stay Center LH Black New 1 12 Clamp - Front Caliper Brake Hose 1

5 Hex Flanged Bolt M8 X 1.25 X 38 2 13 Cross Recessed Pan Head Screw M6 X 14 1

6 Phillips Round Head Machined Screw M6X13 6 14 Plain Washer M6 1

7 Lock Washer M6 6 15 Hex. Nut M6 X 1 X 5 1

8 Hex Nut M6 X 1 6

9 Flanged Hex Bolt M8 X 20 6

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CONTINENTAL GT
A1
8
Key Nos. 8 8
2, 5, 6 & 7 8

6
4
4
6
4 4

7
7
5

5
2 7

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Front Mudguard Mud Flap,Extension Kit 1 6 Pan Head Screw M5 X 0.8 X 12 3

1 Front Mudguard 1 7 Hex. Nut M8 3
2 Mud - Flap Front 1 8 Hex. Socket HD. Cap Screw M6X20
Stainless Steel 4
3 Fork Brace 1
4 Hex. Socket Button Head Screw M6X1 4
5 Lock Washer Internal Teeth 3

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.2 Front Mudguard
Bullet Classic EFI /
Bullet EFI
 Remove Front wheel
as described in Front
Wheel section
 Release Brake hose
grommet from the Flanged Hex bolt: M8
holding clip in front Socket Spanner: 12 mm
mudguard.
 Loosen and remove the
4 flanged hex bolts along
with spring washers,
holding front mudguard,
front, centre & rear stays
to fork end RH.
 Loosen and remove:
- 2 flanged hex bolts Flanged Hex bolt: M8
along with spring Socket Spanner: 12 mm
washers, holding front
mudguard centre stay
& front brake caliper to
fork end LH.
- 2 flanged hex bolts
along with spring
washers, holding front
mudguard front and Socket head cap Screw:
rear stays to fork end M6
LH. Allen Key : 5 mm
 Loosen wheel speed
sensor screw and
remove sensor along
with screw.
 Gently rotate the
mudguard stays into the CAUTION:
mudguard and slide out Ensure mudguard does not
of the fork legs. get scratched while tilting
and removing.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.2 Front Mudguard
Continental GT

 Remove Front wheel

as described in Front
Wheel section

 Loosen and remove the

4 socket head cap Socket head cap Screw:
screws on the fork brace M6
between the fork legs RH
Allen Key : 5 mm
& LH.

 Gently lift up and

remove mudguard from
the fork legs.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.2 Front Mudguard
Bullet Classic EFI /
Bullet EFI CAUTION:
 Locate Mudguard stays Ensure mudguard does
along with mudguard not get scratched while
and slide into the fork assembling.
legs.
 Install wheel speed
sensor screw and locate Socket head cap Screw:
sensor along with screw. M6
 Install and locate: Allen Key : 5 mm
- 2 flanged hex bolts Torque : 25Nm
along with spring
washers, holding front
mudguard centre stay
& front brake caliper to Flanged Hex bolt: M8 X
fork end LH. 38 & M8 X 20
- 2 flanged hex bolts Socket Spanner: 12 mm
along with spring
washers, holding front Torque : 10 Nm
mudguard front and
rear stays to fork end
LH.
 Install and locate the 4
flanged hex bolts along Flanged Hex bolt: M8 X
with spring washers, 20
holding front mudguard, Socket Spanner: 12 mm
front, centre & rear stays
to fork end RH. Torque : 10 Nm
 Locate Brake hose
grommet in the holding
clip in front mudguard.
 Assemble Front wheel
as described in Front
Wheel section.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.2 Front Mudguard
Continental GT

 Gently lift down and

locate mudguard on the
fork legs.

 Install and locate the 4 Socket head cap Screw:

socket head cap screws M6
on the fork brace
between the fork legs RH Allen Key : 5 mm
& LH.
 Locate Front wheel as
described in Front
Wheel section.

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SECTION 6.3 – HANDLE BAR

EXPLODED VIEWS
BULLET CLASSIC EFI / BULLET EFI

A1
3
1
2

4 6

10 7
5
11

9
8

2
1

17 ES
15
12
13
16
14

18

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Handle Bar Assembly Complete 1 9 Lever & Holder Assy. LH 1

1 Hex Socket Head Screw M8 X 50 2 10 Clutch Lever 1
2 Damper Weight 2 11 Switch Module LH 1
3 Hand Grip LH 1 12 Switch Module RH 1
4 Cable Strap 6" 2 13 Rotor Plate 1
Cable Strap 8" 3 14 Pan Head Screw M5 X 10 1
5 Handle Bar Complete 1 15 Front Brake Lever kit 1
6 Rear View Mirror LH 1 16 Add On Lead, Front Brake Switch 1
7 Rear View Mirror RH 1 17 Add On Lead, Clutch Switch 1
8 Grip Complete - Throttle RH 1 18 Clutch Switch 1

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CONTINENTAL GT

A1

Key Nos.
1&2 3
A2 4
5
1
Key Nos. 2
6
24 & 25

7
3 8
3

LH RH
4
5 17 18
13 A2 24 16
25 15
9 14
10
11 15 16 19
A3
12 20
10
21 9
4 22
5 23

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Mirror Set OE - Continental GT 1 12 Switch Module - LH 1

A2 Clutch Switch Repair Kit 1 13 Lever & Holder Assy. - LH 1
A3 Clutch & Front Brake Lever Kit (Clear Coated) 1 14 Handle Bar Complete - LH 1
1 Rear View Mirror - LH 1 15 Hex. Socket Head Bolt M8 X 40 2
2 Rear View Mirror - RH 1 16 Rubber Sleeve - Handle Bar 2
3 Hex. Socket Head Screw M8 X 35 6 17 Handle Bar Complete - RH 1
4 Grommet - Clip ON 2 18 Master Cylinder - Front 1
5 Hex. Socket Head Cap Screw M6 X 20 4 19 Switch Module - RH 1
6 Top Yoke 1 20 Grip Complete - Throttle RH 1
7 Handle Bar Assy. - LH 1 21 Rotor Plate - Throttle Cable 1
8 Handle Bar Assy. - RH 1 22 Pan Head Screw M5 X 10 1
9 Counter Weight Assy. 2 23 Add On Lead, Brake Switch 1
10 Mirror Dummy Ring 2 24 Clutch Switch 1
11 Handle Grip - LH 1 25 Add On Lead, Clutch Switch 1

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Bullet Classic EFI /
Bullet EFI
 Remove Headlamp from Philips head screw driver
the headlamp casing
and disconnect wire
terminals.

 Disconnect wire couplers

Double end spanner
from handle bar inside
15mm
the head lamp casing.

 Remove Rear view

mirrors LH & RH.
 Disconnect all control
cables from the handle
bar.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Bullet Classic EFI /
Bullet EFI
 Remove the 2 hex bolts Hex bolts: M6
on the clamp holding
Front brake master Socket spanner: 10 mm
cylinder to handle bar.

 Remove master cylinder

assembly from the CAUTION:
handle bar and support Ensure the brake lever is not
suitably to prevent depressed while removing
hydraulic oil leak from from handle bar.
master cylinder.

 Loosen and remove 2

Hex bolts along with Hex SS Bolt : M12
washers from the Socket spanner: 14 mm
handle bar clip top.
 Loosen and remove 2
hex nuts along with Hex Nut: M8
washers from the Socket spanner: 12mm
handle bar clip bottom.
 Remove handle bar clip
from the studs in the
headlamp casing and the
handle bar.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Continental GT

 Remove Headlamp from

the headlamp housing Philips head screw driver
and disconnect wire
terminals.

 Disconnect handle bar

LH & RH wire couplers
inside the head lamp
housing.
 Remove Rear view
mirrors LH & RH.

 Disconnect all control

cables from the handle Double end spanner
bar. 15mm

 Remove the 2 hex bolts

on the clamp holding
Front brake master
cylinder to handle bar.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Continental GT

 Remove master cylinder

assembly from the Hex bolts: M6
handle bar and support Socket spanner: 10 mm
suitably to prevent
hydraulic oil leak from
master cylinder.

 Loosen the hex socket

screw clamping the
handle bar assemblies
LH & RH to the fork main
tubes.

 Remove the 2 rubber

grommets on top of the Hex. Socket Head Screw:
handle bar LH & RH and M8
remove the 2 hex socket Allen Key: 6 mm
head cap screws.

Hex. Socket Head Screw:

 Remove handle bar LH &
M6
RH form the fork main
tubes. Allen Key: 5 mm

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Bullet Classic EFI /
Bullet EFI
 Locate handle bar clip on
the studs in the Hex SS Bolt : M12
headlamp casing and the
handle bar. Socket spanner: 14 mm
 Install and locate 2 hex
nuts along with washers
on the handle bar clip Hex Nut: M8
bottom. Socket spanner: 12mm
 Install and locate 2 Hex
bolts along with washers
on the handle bar clip
top.
 Locate master cylinder
CAUTION:
assembly on the handle
bar and support suitably Ensure the brake lever is not
to prevent hydraulic oil depressed while removing
leak from master from handle bar.
cylinder while locating.

 Install the 2 hex bolts on

the clamp holding Front
Hex bolts: M6
brake master cylinder to
handle bar. Socket spanner: 10 mm

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Bullet Classic EFI /
Bullet EFI
 Connect all control
cables on the handle bar.
 Locate Rear view mirrors
LH & RH.

 Connect wire couplers

on handle bar inside the
head lamp casing. Double end spanner
15mm

 Locate Headlamp in the

headlamp casing and Philips head screw driver
connect wire terminals.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Continental GT
 Locate handle bar LH &
RH on the fork main Hex. Socket Head Screw:
tubes.
M8
 Locate the 2 rubber
grommets on top of the Allen Key: 6 mm
handle bar LH & RH and
Install the 2 hex socket
head cap screws.
Hex. Socket Head Screw:
M6
Allen Key: 5 mm

 Install the hex socket Hex bolts: M6

screw clamping the
handle bar assemblies Socket spanner: 10 mm
LH & RH to the fork main
tubes.

 Locate master cylinder

assembly on the handle
bar and support suitably
to prevent hydraulic oil
leak from master
cylinder.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.3 Handle Bar
Continental GT

 Install 2 hex bolts on the

clamp holding Front Double end spanner
brake master cylinder to 15mm
handle bar.

 Connect all control

cables from the handle
bar.

 Locate Rear view mirrors

LH & RH.
 Connect handle bar LH &
RH wire couplers inside
the head lamp housing.

 Locate Headlamp on the

headlamp housing and Philips head screw driver
Connect wire terminals.

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SECTION 6.4 – FRONT FORK

EXPLODED VIEWS
BULLET CLASSIC EFI / BULLET EFI
A1 22
Key Nos. 21 9
20 22
1 to 3, 5 to 20 8
19 21
A2 7
18
Key Nos. 6
1, 2, 4 to 20
17 5
A3
A2 A1
Key Nos. 15
Qty 2 Nos. 2, 7, 9,
11, 15 & 20 11
A4 4

Key Nos. 14 3
16
Qty 2 Nos. 2, 7, 9,
15 & 20
13
A5 24 25

Key Nos. 12 10
23 2
Qty. 2 Nos. 16, 24 1
20 & 22
26 27 28

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Front Fork Assy - LH 1 13 Rebound Spring 2

A2 Front Fork Assy - RH 1 14 Seat Pipe 2
A3 Fork Pipe Spining Replacement Kit 1 15 Piston Ring - Front Fork 2
A4 Fork Oil Seal, ‘O’-Ring & Piston Ring Kit 1 16 Main Spring 2
A5 Main Spring Front Fork Replacement Kit 1 17 Washer - Fork Main Spring 2
1 Socket Headed Bolt 2 18 Spacer Tube - Front Fork 2
2 Copper Packing Washer 2 19 Fork Bolt - Top 2
3 Outer Tube M/C - RH (Fork End) 1 20 ‘O’ Ring - Fork Bolt Top 2
4 Outer Tube M/C - LH (Fork End) 1 21 Plain Washer - Fork Bolt 2
5 Guide Bush 2 22 Flange Bolt 2
6 Plain Washer Big 2 23 Hex Nylock Nut M8 X 9.5 1
7 Oil Seal - LH & RH Front Fork 2 24 Punched Washer 2
8 Oil Seal Stopper - LH & RH 2 25 Flanged Hex. Bolt M8 X 55 (Special) 1
9 Dust Seal - LH & RH 2 26 Reflex Reflector (Amber) 2
10 Slide Bush 1 27 Wheel Speed Sensor-ABS 1
11 Fork Pipe Spining - Inline Fork 2 28 Hex.Socket Button Head Screrw M6X1X16 1
12 Cap Oil Lock (Spindle Tapper) 2

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CONTINENTAL GT
A1 A2 24 26

Key Nos. Key Nos.

All Except 2 All Except 1 & 19
17
25 16
A3 18
22
Key Nos. 3
15
A2 A1
Each Qty. 2 Nos.
14
3, 7, 9, 11, 17 & 20
A4
13 9
Key Nos. 2 8
7
QEach Qty. 2 Nos. 6
5 23
7, 9, 11, 17 & 20 20
26
25
21 24
A5
4 1
Key Nos.
(Qty. 2 Nos. 13), 10 19
16 & 17 12
11

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Fork End LH assy 1 13 Spring – 1 2

A2 Fork End RH assy 1 14 Washer Spring Top 2
A3 Fork Pipe Spinning Replacement Kit 1 15 Spacer 2
A4 Fork Oil Seal, ‘O’ Ring & Piston Ring Kit 1 16 Bolt Cap 2
A5 Main Spring Fork Major Kit 1 17 ‘O’ Ring 2
1 Outer Tube - RH 1 18 Washer - 2 2
2 Outer Tube - LH 1 19 Bolt M8 X 1.25 X 45 2
3 Inner Tube Assy. 2 20 Piston Ring 2
4 Piston - Front Fork 2 21 Spring - 2 2
5 Bush (Outer Tube) 2 22 Cable Guide - Brake 1
6 Bush Washer 2 23 Cable Guide - Speedo Cable 1
7 Oil Seal 2 24 Hex. Bolt M6 X 12 2 2
8 Circlip (Snap - Ring) 2 25 Plain Washer 2
9 Dust Seal 2 26 Lock Washer, M6 2
10 Spindle Taper 2 27 Reflex Reflector Amber 2
11 Gasket 2 28 Wheel Speed Sensor-ABS 2
12 Bolt M10X1 2 29 Hex.Socket Button Head Screrw M6 X 1X 16 1

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Bullet EFI / Bullet
Classic EFI
 Remove Front wheel as
described in Front
Wheel section 6.1.
 Remove front mud-
guard as detailed in
Section 6.2.
 Ensure wheel speed
sensor is removed from
the fork end LH.

 Disconnect Trafficator
couplers LH & RH inside
headlamp casing.
 Loosen Hex Nylock nuts
Hex Nylock Nut: M8
on steering stem pinch
bolt LH & RH remove Ring spanner: 12mm
trafficator assembly
with bracket on LH & RH
Hex bolt M8
side.
Hex Nylock Nut: M8
 Hold the pinch bolts LH
& RH and loosen hex nut Double end spanner:
Loosen nut by holding 12mm
fork pinch bolt in bottom Ring spanner: 12mm
yoke (steering stem) on
RH & LH side.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Bullet EFI / Bullet
Classic EFI
 Loosen and remove 2
Hex socket screws from
the top of the front forks
on the head lamp casing.

 Gently rotate and Hex Hd Cap screw M10

remove the fork
assembly LH & RH from Allen Key 8 mm
the head lamp casing
and the steering stem.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Continental GT
 Remove Front wheel as
described in Front
Wheel section 6.1.
 Remove front mud-
guard as detailed above
in Section 6.2.
 Ensure front brake
caliper is dismantled
from the fork LH.
 Ensure wheel speed
sensor is removed from
the fork end LH.

Hex bolt M8
T spanner 12 mm

 Remove Headlamp from Hex. Socket Screw M8

the headlamp housing
and disconnect all Allen key 6 mm
electrical connections
inside headlamp housing.
 Loosen and remove the
2 hex bolts holding head
lamp housing to the
holder RH & LH.

 Loosen the 2 hex socket

screws inside the head
lamp holder RH & LH.
Ensure the head lamp
holders are free on the
front fork main tube.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Continental GT
 Loosen the 4 hex socket Hex Screw M6
head cap bolts (2 each
on LH & RH sides) from Allen key 5 mm
the steering stem.
 Loosen the 4 hex socket
head cap bolts (2 each
on LH & RH sides) from
the top yoke.

 Gently rotate and

NOTE:
remove the forks LH &
RH from the steering Support the head lamp
stem and top yoke. holders with the trafficators
while removing the forks LH
& RH from the steering stem.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Bullet EFI / Bullet
Classic EFI
Hex Screw M10
 Gently rotate and locate
the fork assembly LH & Allen Key 8 mm
RH on the head lamp
casing and the steering
stem.

 Install and locate 2 Hex

socket screws in the top
of the front forks on the
head lamp casing.

 Hold the pinch bolts LH

& RH and Install hex nut
Loosen nut by holding
fork pinch bolt in bottom Hex bolt M8
yoke (steering stem) on
RH & LH side. Hex Nylock Nut: M8
 Install Hex Nylock nuts Double end spanner:
on steering stem pinch 12mm
bolt LH & RH and locate Ring spanner: 12mm
trafficator assembly with
bracket on LH & RH side.
 Connect Trafficator Hex Nylock Nut: M8
couplers LH & RH inside
headlamp casing. Ring spanner: 12mm

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Bullet EFI / Bullet
Classic EFI
 Ensure wheel speed
sensor is located in the
fork end LH.
 Locate front mudguard
as detailed above.
 Assemble Front wheel
as described in Front
Wheel section 6.1.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Continental GT
 Locate the fork assem-
bly LH & RH on the head NOTE:
lamp casing and the
steering stem. Support the head lamp
holders with the trafficators
 Gently rotate and locate
the forks LH & RH on the while removing the forks LH
steering stem and top & RH from the steering stem.
yoke.

 Install the 4 hex socket

Hex Socket Screw M6
head cap bolts (2 each
on LH & RH sides) on the Allen key 5 mm
top yoke.

 Install the 4 hex socket

head cap bolts (2 each
on LH & RH sides) on the
steering stem.
 Install the 2 hex socket
screws inside the head
lamp holder RH & LH.
Ensure the head lamp
holders are fixed on the
front fork main tube.
 Install and locate the 2
hex bolts holding head
lamp housing to the
holder RH & LH.
 Locate Headlamp in the Hex Socket Screw M8
headlamp housing and Allen key 6 mm
connect all electrical
connections inside
headlamp housing.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork LH & RH
Continental GT
 Ensure wheel speed
sensor is located in the Hex bolt M8
fork end LH.
T spanner 12 mm
 Ensure front brake
caliper is located in the
fork LH.
 Locate front mudguard
as detailed above.
 Assemble Front wheel
as described in Front
Wheel section 6.1.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork Oil
Draining

 Hold the fork assembly

in bench vice with soft Hex nut M16
jaws, approximately 6 Double end spanner
inches from the top and 24 mm
loosen top nut.
 Remove fork assembly
from the bench vise.
 Hold upright and gently
remove fork top nut with
washer, allowing spring
to expand slowly.

 Remove washer, spacer

and washer spring top NOTE:
from the inner tube. Replace all Rubber parts, ,
plastic bushes, O rings,
washers whenever they are
removed.

 Remove long spring

from inner tube.

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 S. Aggregate to Dismantle/
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork Oil
Draining
 Invert the fork assembly
to drain out the oil from
the fork.
 Gently pump main tube
into the bottom tube to
drain out the oil
completely.

 Repeat the above process

to drain oil from the
other fork assembly.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork Oil
Filling

 Fill Fork oil 195 ml/leg

(For Bullet & Classic
Models) and 430 ml/leg
(For Conti-GT Model)
with 2W 35 Grade.

 Locate long spring into

the inner tube.

 Locate washer, spacer

and washer spring top in NOTE:
the inner tube. Replace all Rubber parts, ,
plastic bushes, O rings,
washers whenever they are
removed.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork Oil
Filling

 Locate fork top nut with

washer, allowing spring Hex nut M16
to compress slowly. Double end spanner
24 mm

 Repeat the above

process to fill oil and
assemble the other fork
assembly.

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 S. Aggregate to Assemble/
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork
Assembling

 Remove the pinch bolt

and nut on Fork RH. Hex bolt & nut: M6

 Locate special tool Ring spanners: 10mm

inside inner tube such
that it engages with the
Special Tool: ST-25834-2
nut on the seat pipe
inside. Allen Key: 10mm

 Loosen and remove the

hex socket head nut
inside the outer tube.

 Remove the special tool

from the inner tube.

 Remove the dust seal,

retainer clip, and fork
seal from the outer tube.
 Pull out the inner tube
from the outer tube
sharply to remove the
inner tube along with the
guide bush, seat pipe
assembly, rebound
spring and cap oil lock.

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 S. Aggregate to Dismantle/
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.4 Front Fork
Dismantling

 Pull in the inner tube on

the outer tube sharply
to locate the inner tube
along with the guide
bush, seat pipe assembly,
rebound spring and cap
oil lock.

 Locate the dust seal,

retainer clip, and fork
seal in the outer tube.

 Locate the special tool in

the inner tube.

 Locate and install the

hex socket head nut
inside the outer tube.
 Locate special tool Special Tool: ST-25834-2
inside inner tube such Allen Key: 10mm
that it engages with the
nut on the seat pipe inside.
Hex bolt & nut: M6
 Locate the pinch bolt
and nut on Fork RH. Ring spanners: 10mm

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INSPECTION
Inspect front fork inner tube for any damages and bends.
Inspect front fork outer tube for any damages, cracks at oil seal seating area.

WEAR LIMIT
 Fork spring long

Spring Length ------ mm

Long Pitch Short Pitch

 Fork spring short

Length
New Spring: --------mm
Service Limit: -------mm

Main tube straightness

Service Limit: 0.15 mm

Guide Bush

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SECTION 6.5 – STEERING STEM

EXPLODED VIEWS
BULLET CLASSIC EFI / BULLET EFI
13 15 16
12
10 14
16
12 15
11 17 14
21
1
20
25
2 19
3 18
4 28

1
22
4 23 22
3
23
5
24

24 27
6
9
9

26

7
8 7
8

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Cover 2 15 Washer 2
2 Ball Race, Head Lamp Casing 1 16 Nut 2
3 Steering Stem Ball Cage 2 17 Clip, Handle Bar 1
4 Ball Race, Frame 2 18 Sleeve, Threaded 1
5 Ball Race, Fork Crown 1 19 Sleeve, Plain 1
6 Steering Stem Assy. 1 20 Hex Socket head Cap Screw M10 x 1.5 x 35 1
7 Flanged Hex Nut M8 x 7.7 X 8 2 21 Adaptor AHO 1
8 Hex Nut with Nylock insert - M8 X 9.5 2 22 Rubber Spacer 2
9 Flange Bolt (M8 × 75) 2 23 Bush 2
10 Stem Lock Nut 1 24 Cover Tube 2
11 Steering Stem Lock Nut Washer 1 25 Head Lamp Casing 1
12 Washer 2 26 Rr Cover Comp C5 1
13 Hex SS Bolt M8 x 48 2 27 Slotted Rd. Hd.Screw 2
14 Stud (M8×32) 2 28 Rubber Grommet 2

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CONTINENTAL GT

1
3
4
5
6
2 7
3 8

9
8

10

7 11
12 3

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Lock Nut 1 8 Ball Race - Frame Head Tube 2

2 Top Yoke 1 9 Dust Cap - Frame 1

3 Hex. Socket Head Bolt M8 X 35 8 10 Steering Stem Assembly 1

4 Ring Nut 2 11 Ball Race - Bottom Yoke 1

5 Dust Cap - Top Yoke 1 12 Dust Seal - Bottom Yoke 1

6 Ball Race - Top Yoke 1

7 Steering stem - Ball Cage 2

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Steering Play
Adjustment
Bullet Classic EFI /
Bullet EFI
 Rock the front end and
feel the play at stem top NOTE:
end. Every 6,000 KMS, Steering
Ball race adjustment should
be done and on Every
12,000 Km Lubrication is
recommended.

If felt, adjust as follows:

Lock Nut M20
 Loosen steering bottom
bridge pinch bolt and Socket Spanner - 30 mm
nuts of Right & Left side.
 Loosen the stem lock nut
and then tight steering
stem tapper nut to
adjust excess play.
 Again re-check play, it
should be free without
any play.
 Finally tighten all the Dome Lock Nut M24
nuts and bolts in reverse
order. Socket Spanner – 30 mm
Torque – 50 Nm

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Steering Play
Adjustment
Continental GT
 Place Motorcycle on
Center Stand.
 Keep a wooden plank
under the stand to Rise
the Front Wheel.

 Hold the Fork pipe (Main

CAUTION: CAUTION:
Tube) pull and push
simultaneously lift the Do not Use Sockets
Do not Use Sockets Directly.
front wheel upwards Directly.
and check for Steering
play.
 Rock the front wheel
down wards and feel the Dome Lock Nut M24 
play / sound at stem top
dome nut by fingers. Socket Spanner – 30 mm
Steering
Dome Nut Don’t X
If felt, adjust as follows : Hex Socket Screw M5
 Loosen the steering Allen Key 6mm
dome nut with long
extension rod.
 Loosen the pinch bolts in
bottom yoke on LH and
then RH side.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Steering Play
Adjustment
Continental GT
 Loosen the lock ring nut
before adjusting
Steering play.

 In case of excessive
C Spanner
steering play tighten the
steering ring nut by
using special tool (C
spanner).

 After adjusting the play

then tighten lock nut
CAUTION:
against ring nut. Do not use Ring spanner
directly to tighten dome
nut.

 After adjusting the play

Dome Lock Nut M24
then tighten Dome nut
to Torque. Socket Spanner – 30 mm
Torque – 50 Nm

 Again check and confirm

the steering free play.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Steering Play
Adjustment
Continental GT
 Tighten the pinch bolts Hex Socket Screw M5
in bottom yoke LH and
then RH by using Allen Allen Key 6mm
key. Torque 25 NM

 Now check the handle NOTE:

bar free movement by
turning extreme Left to Take a small test ride to
Right side. ensure that
- Steering free movement.
- No dragging.
- No sound from steering
stem / mounting area.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI /
Bullet EFI
 Disconnect speedometer
cable from the
speedometer.
 Disconnect wiring
couplers of the speedo-
meter, MIL meter,
ignition switch and
parking lamps from the
main wiring harness.
 Remove the clutch,
throttle and bi-starter
cables from the hole in
the headlamp casing.
 Loosen & remove the
hex Nylock nut and bolt
holding RR cover and
cover tube to the
steering stem.
 Loosen socket head
screw in the head lamp Hex Soc Hd Cap screw:
casing inner side by 3 to M10
4 threads. Allen key 12 mm
 Support the steering
stem at the bottom.

 Loosen and remove the

steering stem lock nut Hex nut (Steering stem
from the headlamp lock nut) : M24
casing along with the Ring spanner: 30mm
washer.
 Remove the fork cover
tubes LH & RH along with
the rubber spacers and
plastic bushes.

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 S. Aggregate to Dismantle/
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI /
Bullet EFI
 Gently lower the
steering stem and
remove from the frame.
 Remove the Headlamp
casing from the frame.

 Remove the top and

bottom ball cage from
the ball races.

 Using a long chisel, gently

tap and drive out the top
and bottom races from
the frame head tube
along with the dust cap.

 Using a short chisel, drive

out the ball race along
with dust cap from the
headlamp casing and the
ball race from steering
stem.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI /
Bullet EFI
 Using a short chisel, drive
in the ball race along with
dust cap on the
headlamp casing and the
ball race in steering
stem.

 Using a long chisel, gently

tap and drive in at the
top and bottom races on
the frame head tube
along with the dust cap.
 Locate the top and
bottom ball cage from
the ball races.
 Locate the Headlamp
casing in the frame.

 Loosen and remove the

steering stem lock nut
from the headlamp
casing along with the
washer.
 Remove the fork cover
tubes LH & RH along with
the rubber spacers and
plastic bushes.
 Locate steering stem
and assemble on the
frame.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Headlamp Casing &
Steering Stem
Bullet Classic EFI /
Bullet EFI
 Locate the fork cover
tubes LH & RH along with
the rubber spacers and
plastic bushes.
 Locate and install the
steering stem lock nut in
the headlamp casing
along with the washer.
 Locate the fork cover
tubes LH & RH along with
the rubber spacers and
plastic bushes.
 Locate and install the
steering stem lock nut in
the headlamp casing
along with the washer.

 Install socket head

screw in the head lamp Hex Soc Hd Cap screw:
casing inner side by 3 to M10
4 threads. Allen key 12 mm
 Locate & Install the hex
Nylock nut and bolt
holding RR cover and
cover tube to the
steering stem.
 Locate the clutch,
throttle and bi-starter Hex nut (Steering stem
cables on the hole in the
headlamp casing. lock nut) : M24
 Connect wiring couplers Ring spanner: 30mm
of the speedometer, MIL
meter, ignition switch, Torque: 70 Nm
and parking lamps in the
main wiring harness.
 Connect speedometer
cable from the speedo-
meter.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Top Yoke & Steering
Stem
Continental GT
 Disconnect all wiring
couplers of the
instrument cluster to
main wiring harness.
 Remove speed sensor
wire coupler from wiring
harness.

 Remove the top lock nut

on the top yoke.
 Remove the top yoke
along with the
instrument cluster and
ignition switch.

 Support steering stem

and the bottom and
loosen and remove the
top ring nut first and the
second ring nut next.

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 S. Aggregate to Dismantle/
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Top Yoke & Steering
Stem
Continental GT

 Gently lower the

steering stem and
remove from the frame.

 Remove the top and

bottom ball cage from
the ball races.

 Using a long chisel, gently

tap and drive out the top
and bottom races from
the frame head tube
along with the dust cap.
 Using a short chisel, drive
out the ball race along
with dust cap from the
top yoke and the ball
race from steering stem.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Top Yoke & Steering
Stem
Continental GT
 Using a short chisel, drive
in the ball race along with
dust cap in the top yoke
and the ball race on
steering stem.
 Using a long chisel, gently
tap and drive in at the NOTE:
top and bottom races
from the frame head Replace all Rubber parts, ,
plastic bushes, O rings,
tube along with the dust
washers whenever they are
cap.
removed.

 Locate the top and

bottom ball cage in the
ball races.

 Locate steering stem

and assemble on the
frame.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
6.5 Top Yoke & Steering
Stem
Continental GT
 Locate and install the
second ring nut first and
top ring nut next.
 Locate the top yoke
along with the instrument
cluster and ignition
switch.

 Locate the top lock nut

on the top yoke.

 Locate speed sensor

wire coupler from wiring
harness.
 Connect all wiring
couplers of the
instrument cluster to
main wiring harness.

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INSPECTION
Inspect the steering ball cages and ball races for any rusting, pitting and damaged balls/ races
Inspect steering stem for any damages / run out as these will affect the stability and steer ability for the motorcycle

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 SECTION 07 - REAR SUSPENSION

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SECTION 7.1 - REAR WHEEL

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI
12

11
10
23 24 25
13 20 21 22
14 18 19 6
15 17
16

6 7 8 9 1
5
4 20

3
2
19
28

1
29 30

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Socket Head Bolt M8 X1.25 X20 6 17 Cush Rubber 4

2 Toner-Rear Wheel 1 18 Adaptor-Rd Sprocket 1
3 Spindle Long 1 19 Sprocket-Rear Drive 1
4 Rear Disc Plate 1 20 Low Head Socket Cap Screw M10 X 1.5 X 16 6
5 Spacer-Disc Side 1 21 Bearing 1
6 Grease Seal,25X40X7 2 22 Dust Seal-Rd Spracket 1
7 Deep Groove Ball Bearing 6203 (17X40X12) 2 23 Spindle Short 1
8 Rear Hub Spacer Assy 1 24 Spacer-Sprocket Side 1
9 Rear Hub 1 25 Hexognal Lock Nut M22X1.5 1
10 Spokes Outer Rear 20 26 Washer 1
11 Spokes Inner-Rear 20 27 Hex U Nut M16X1.5 1
12 Brass Nipples 40 28 Final Drive Sprocket 17T 1
13 Tyre-Rear 110/80 - 18" 1 29 Chain Rear (102 Pitches O-ring type) 1
14 Tube-Rear 110/80 - 18" 1 30 Connecting Link ‘O’ Ring Drive Chain - LGB 1
15 Rim Rear 1
15 Wheel Rim Amry Og 1
16 Rim Tape 1

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CONTINENTAL GT

27
25 26 28
15 16 17 24
21
18 22 23
20
19

14
13
12
11
9 10 21
8
7
6

4 5

3
2 8 7
1 20
29

4 30 31

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Spindle Long 1 17 Rim Rear 1
2 Washer 1 18 Rim Tape 1
3 Spacer-Disc Side 1 19 Adaptor – RD Sprocket (Metalic Silver) 1
4 Hex.Socket Button Head Screrw M6X1 X 14 6 20 Sprocket-Rear Drive 1
5 Toner-Rear Wheel 1 21 Low Head Socket Cap Screw M10 X 1.5 X 16 6
6 Rear Disc Plate 1 22 Bearing 6005 (25 X 47 X12) 1
7 Grease Seal,25X40X7 2 23 Dust Seal-Rd Spracket 1
8 Deep Groove Ball Bearing 6203 (17X40X12) 2 24 Spindle Short 1
9 Spokes Inner-Rear 18 25 Spacer-Sprocket Side 1
10 Bearing Spacer Assy 1 26 Hexognal Lock Nut M22X1.5 1
11 Rear Hub Assembly 1 27 Washer 1
12 Spokes Outer-Rear 18 28 Hex U Nut M16X1.5 1
13 Brass Nipples 36 29 Final Drive Sprocket 17T 1
14 Cushion Rubber 4 30 Chain Rear (100 Pitches O-ring type) 1
15 Tyre-Rear 130/70 – 18” 1 31 Connecting Link ‘O’ Ring Drive Chain - LGB 1
16 Tube-Rear (130 /80 – 18") 1

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.1 Rear Wheel
Dismantling
Bullet Classic EFI/
Bullet EFI /
Continental GT
 Place the motorcycle on
its center stand, on a firm
and flat surface such
that the rear wheel is
about 4 inches (10 cms)
above the ground.
 Observe and mark the
alignment index marks in
the both sides of swing
arm.

 Hold the axle from the Hex Nut M16

left side.
Double end spanner 24mm

 Loosen and remove the

hex nut on the right side.

 Remove wheel spindle

from left side.

 Gently release the brake

hose from the holding
clips in the swing arm.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.1 Rear Wheel
Dismantling
Bullet Classic EFI/
Bullet EFI /
Continental GT
 Remove the caliper CAUTION :
assembly by gently Do not press the rear brake
pulling out from the pedal when wheel is
swing arm slot and removed as this will result in
support the caliper the brake pads coming too
suitably. far out of the brake caliper.
Place a 4 mm thick wooden
piece or cardboard sheet
between the brake pads to
 Ensure the spacer is avoid pads activation in the
removed and stored event if the rear brake pedal
carefully. is accidently pressed.

 Gently pull rear wheel

towards the left so that
the hub becomes free
from the lugs in the
sprocket.

 Slide out the rear wheel

assy. from the swing
arm.

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INSPECTION
 Inspect tyres for any side wall crack stone hits, bulge, proper seating in rim.
 Tyres button to be above the tyre wear indicator mark on the side walls.
 Inspect spokes for any loosening / breakage.
 Inspect hub or any damage.
 Inspect Toner ring for any damage.
 Axle & nut for thread damage.
 Inspect wheel rim for run out / “jump” it should not exceed 2 mm.
 Inspec cush rubbers for wear or deterioration and replace only as set if required.

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WEAR LIMITS
Rear wheel disc flatness & run out BRAKE DISC
Minimum disc thickness marked on disc
A B
Front Disc

Rear Disc

UCE 535
A B
New Min. Flatness 0.00 mm 0.00 mm
New Max. Flatness - 0.10 mm
Service Limit :
Run out - disc

Rear Disc
Thickness
(BBI)

CON. GT
New Min. 5.00 (only GT)
New Max. -
Service Limit 4.5 mm

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.1 Rear Wheel
Assembling
Bullet Classic EFI/
Bullet EFI
 Remove the wooden
piece / card board sheet
placed between the
brake pads.
 Ensure the four Cushion
rubbers are in position in
the rear wheel hub.
 Position rear wheel
swing arm such that he
brake disc is on the left
side.

 Locate rear wheel on the

sprocket, ensuring the NOTE :
cushion rubbers are Ensure the brake disc is
seated on the lugs located in between the
correctly. brake pads.
 Locate the caliper
assembly on the lug in
the swing arm.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.1 Rear Wheel
Assembling
Bullet Classic EFI/
Bullet EFI

 Ensure the Chain

tensioner is correctly
located inside the swing
arm on the left side &
firmly seated against
swing arm.

 Position the spacer

correctly between the
hub and the caliper
assembly.

 Align the caliper bracket,

spacer, hub and chain NOTE :
tensioner holes. Ensure the caliper brake,
spacer chain tensioner hub
 Insert the wheel spindle mounting bolts are aligned.
from left side fully.

 Hold the axle from the Hex nut M16

left side and tighten the
axle nut on the right side. Double end spanner 24mm
Torque – 70 Nm
 Gently locate the brake
hose into the holding
clips in the swing arm.

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SECTION 7.2 - REAR SPROCKET (DRIVE CHAIN ADJ.)

S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.2 Drive chain free
play adjustment
 Remove the split pin
from the castle nut. 20 to 25 mm

 Loosen the Castle/

spindle nut

Castle
spindle Nut

Split Pin

 Loosen the locknut of

each end of the swing
arm. Index Mark Drive Chain slack
adj. nut

Swing Arm Reference Mark Lock nut

 To reduce the free play,

turn the drive chain
slack adjusting nut at
each end of the swing
arm in Clockwise
direction.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.2 Drive chain free
play adjustment
 To increase the free play,
turn the drive chain
slack adjusting nut at
each end of the swing
arm in anticlockwise
direction and push the
rear wheel forward.

 Check the front and rear

wheels correctly aligned.

 Check and ensure the Torque: 70 Nm

alignment marks on each
side of the swing arm.
Hex lock nut M8

 Finally torque the castle/ Double end spanner – 13

spindle nut. mm

CAUTION:
 Tighten the lock nut for
the chain slack adjusting Improper drive chain slack
nut. will overload the engine
and It leads to chain
slippage or breakage. It is
recommended to maintain
drive chain slack within the
specified limits.

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SECTION 7.3 – REAR SHOCKERS

EXPLODED VIEWS
REAR SHOCKABSORBER

Bullet & Classic Continental GT

LH
3
RH
5
7
6 5
5 6
8 6 5
7
5
4 2 5 6
1 8

9
1

5
6
7
5
6
7

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Shockabsorber - Chrome Plated 2 6 Single Coil Spring Lock Washer 4

2 Shock Absorber 2 7 Domed Nut 4
3 Hex Bolt - 3/8"X45 (For RH Side Only) 1 8 Flanged Hex. Bolt M10 x 44 2
4 Hex Bolt - 3/8" BSF x 2" (For LH Side Only) 1 9 Spring - Shock Absorber 2
Plain Washer (M10) 6
5
Plain Washer (M10) 2

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.3 Rear Shock absorber
Adjustment
Bullet Classic EFI /
Bullet EFI /
Continental GT
 The Pre-loaded spring
tension shockabsorber CAUTION: C5/B5
is of adjustable type i.e., Riding the motorcycle with
the spring tension can be the notches adjusted in
increased or reduced. different positions can
cause loss of control and
 The spring tension of the may lead to an accident.
rear shockabsorbers Regularly inspect shock-
can be increased or absorbers and front forks
decreased to suit for leaks. Replace worn
different riding conditions. parts. Worn parts can
adversely affect stability
 The adjuster provided at and handling.
the bottom of the spring
has five notches and can
be rotated using a Special Tool:
special ‘C’ spanner. C Spanner
 Rotate adjuster “clock-
wise” to increase spring
tension and “anti-
clockwise” to reduce
spring tension.
 Ensure the spring
tension is the same in NOTE: GT
both the left and right Ensure no fouling of any
side shockabsorbers accessories with rear Shock-
absorber. Check for
 After adjustment, sufficient gap availability
ensure the adjuster between the shockabsorber
notches are seated and the attachments when
correctly against the peg the rear end of the motor-
in the shockabsorber. cycle is fully loaded and the
shock absorbers are fully
compressed.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.3 Rear Shockers
Bullet Classic EFI /
Bullet EFI
Dismantling
 Refer Rear Mudguard
Section 7.4.

 Loosen 2 domed nuts

mounted on top end of Domed Nut M10
rear shock absorbers on Hex Bolt M6
both LH & RH sides along
with single coil spring Socket Spanner 10mm
lock washer and plain
washer.

 Remove 2 Hex bolts

mounted on the inner
side of Rear shock
absorbers top end on
both LH & RH sides along
with plain washer.

 Loosen 2 Domed nuts

mounted on bottom
end of rear shock
absorbers on both LH &
RH side along with single
coil spring washers and
plaint washers.

 Gently remove the Rear

Shockabsorbers (Chrome
plated) from LH & RH
side.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.3 Rear Shockers
Continental GT

 Loosen 2 hex bolts

mounted on top end of Flanged Hex Bolt M 10
Rear shock absorbers Socket Spanner 17 mm
on both LH & RH sides
along with single coil
spring lock washers and
plain washers.

 Loosen 2 domed nuts

mounted on bottom
end of rear shock
absorbers on both LH &
RH sides along plain
washer

 Gently remove the Rear

Shock Absorbers from
LH & RH side.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.3 Rear Shockers
Bullet Classic EFI /
Bullet EFI
 Locate Rear Shock
Absorbers(Chrome
plated) on LH & RH side

 Install 2 Domed nuts on

bottom end of rear Domed Nut M10
shock absorbers on both Hex Bolt M6
LH & RH side along with
single coil spring washers Socket Spanner 10mm
and plain washers. Torque 4 Kg-M

 Install 2 Hex bolts on the

inner side of Rear shock
absorbers top end on
both LH & RH sides along
with plain washer.

 Install 2 domed nuts on

top end of Rear shock
absorbers on both LH &
RH sides along with
single coil spring lock
washer and plain washer

 Refer Rear Mudguard

assembling Section 7.4.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.3 Rear Shockers
Continental GT

 Locate Rear Shock

Absorbers on LH & RH
sides.

 Install 2 Domed nuts on

bottom end of rear Flanged Hex Bolt M 10
shock absorbers on both Socket Spanner 17 mm
LH & RH side along with
Torque 4 Kg-M
single coil spring
washers and plain
washers.

 Install 2 hex bolts on top

end of Rear shock
absorbers on both LH &
RH sides along with
single coil spring lock
washers and plain
washers.

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SECTION 7.4 - REAR MUDGUARD

EXPLODED VIEWS
BULLET EFI
13
14
12
3
5 1 17 6
10
2 17
6 9
7 6
4 7
25 26
27 11
8
16 18
6 21
22 7 7
23 24
6 5
4
7 3
29 6
7 7
6 23
8 20
28 27
26

25 21

35
6 28

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Rear Mudguard With Sticker Std BVI 1 16 Hex Nut M6X1 2

2 Mudguard Carrier RH Mod Black 1 17 Lock Washer Internal Teeth M6 8
3 Flanged Hex. Bolt M8 X 20 2 18 Piece Mudguard 1
4 Hex. Nut With Nylon Insert M8 X 9.5 2 19 Washer Plain M6 2
5 Crossed Raised Pan Head Screw M6 X 14 2 20 Hex. Bolt M6 X 35 2
6 Plain Washer M6 10 21 Mudguard Carrier LH Mod Black 1
7 Hex. Nyloc Nut M6 9 22 Faced Hex. Nut 1/2” CEI 2
8 Plug - Carrier End 2 23 Rear Mudguard Carrier Stud Bottom 2
9 Grommet 1 24 Plain Washer M12 4
10 Beading - Rear Number Plate 1 25 Flanged Hex Bolt M10 X 1.25 X 50 2
11 Hex. Bolt, M8 X 30 1 26 Plain Washer M10 2
12 Number Plate Holder Complete 1 27 Washer Faced Nut M10 (Metric) 2
13 Tail Lamp Bracket Complete 1 28 Screw M6 X 15 2
14 Beading 1 29 Bridge Plate 1
15 Reflector 1

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BULLET CLASSIC EFI

8
6
3 22
19
7
5
4 18 21
5 20
4 5
4
1
9
16 4
16
10 4
2 4 11
12
5
13
8 4
7 5 14
4
5
17 16

6 4

29
9

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Rear Mud.Comp. W/Stick-Cl. Black BVI 11 12 Number Plate Holder Comp Black 1
2 Mudguard Carrier Assy LH - C5 Black 1 13 Tail Lamp Bkt Comp Black Mod 1
3 Mudguard Carrier Assy RH Classic Black 1 14 Beading 1
4 Plain Washer M6 6 15 Reflector Assembly 1
5 Hex. Screw M6 X 1 X 16 6 16 Hexagonal Nut M6 X 1 X 7 4
6 Hex. Socket Head Screw M8 X 40 2 17 Flanged Hex. Bolt M8 X 30 1
7 Hex. Nylock Nut M8 X 9.5 2 18 Piece Mudguard 1
8 Flanged Hex. Bolt M8 X 1.25 X 45 2 19 Lock Washer,Internal Teeth 2
Dome Cap Bolt M8 X 45 (Special) 2 20 Hex Bolt, M6 X 35 2
9 Plug Carrier End 2 21 Washer Plain 2
10 Grommet 1 22 Hex. Nut M6 2
11 Beading 1

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CONTINENTAL GT

16

9 3
11 13 16

15 14 17
18 11
11 1
19 17 5
11
4
8
18
19

2
10

12
20
12

20
21

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Rear Mudguard 1 12 Hex Nut With Nylon Insert, M8 2

2 Mudflap-Rear 1 13 Lock Washer, M6 2
3 Tail Lamp Bkt Comp 1 14 Washer 2
4 Rubber Pad-Tail Lamp 1 15 Hex.Nut M6 2
5 Number Plate Mtg Bracket – Rear Plate (Export) 1 16 Hex.Socket Button Head Screrw M6 X 16 2
6 Number Plate – Rear Export 1 17 Hex.Nut With Nylon Insert M6 2
7 Tail Lamp 1 18 Cross Recessed Pan Head Screw M6X 4 2
8 Trafficator Assy With Bulb-Rear LH 1 19 Punched Washer M6 2
9 Trafficator Assy With Bulb-Rear RH 1 20 Hex.Nut With Nylon Insert M6 2
10 Reflector 1 21 Flange Hex Bolt M6 X 20 2
11 Flanged Hex.Bolt, M8 X 1 X 20 4

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.4 Rear Mudguard
Bullet Classic EFI /
Bullet EFI
 Loosen 2 hex bolts
mounted on top end of Flanged Hex Bolt M8
Mudguard Carrier on Socket spanner 13 mm
both LH & RH side along
with washer.

 Remove 2 Hex screws

mounted on bottom Hex Socket head cap
end of Mudguard carrier Screw M8
on both LH & RH side. Allen Key 5 mm

 Gently remove the Rear

Mudguard assembly
along with Mudguard
carriers.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.4 Rear Mudguard
Continental GT

 Refer Section 5.4

removal of Seat
dismantling

 Loosen 2 hex bolts

mounted on top end of Flanged Hex Bolt M8
Rear mudguard along Socket Spanner 13 mm
with Hex nuts

 Loosen 2 hex screws

mounted on rear end of Cross recessed pan head
Rear mudguard along screw M6
with punched washers Allen Key 5 mm

 Gently remove the Rear

mudguard from its
position

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.4 Rear Mudguard
Bullet Classic EFI /
Bullet EFI
 Gently locate the Rear
Mudguard assembly Hex Socket head cap
along with Mudguard Screw M8
carriers. Allen Key 5 mm

 Install 2 Hex screws on

bottom end of Flanged Hex Bolt M8
Mudguard carrier on Socket spanner 13 mm
both LH & RH side.
Torque 3 Kg-M

 Install 2 hex bolts on top

end of Mudguard Carrier
on both LH & RH side
along with washer.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.4 Rear Mudguard
Continental GT

 Locate the Rear

mudguard on its
position.

 Install 2 hex screws on

rear end of Rear Cross recessed pan head
mudguard along with screw M6
punched washers Allen Key 5 mm

 Install 2 hex bolts on top

end of Rear mudguard Flanged Hex Bolt M8
along with Hex nuts Socket Spanner 13 mm

 Refer Section 5.4 for

assembling Seat dis-
mantling .

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SECTION 7.5 - REAR SWING ARM

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI

5
3

9 4

9
8
1
2 12
11

11

2
3
6
7
10

15
14 13 16
15 16
16
16
A1

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Swing Arm Sub Assembly Black 1 Black-Powder Coated 1

2 Swing Arm Bush - Celcon 2 11 Flange Bolt with Collar - M6 X 1 2
3 End Cup 2 12 Chain Guard 1
4 Spacer - Chain Stay 1 13 Chain Tensioner RH 1
5 Hex. Flanged Bolt 1/2 X 16 TPI X 240 - T30 1 14 Chain Tensioner LH 1
6 Washer - Shake Proof M12 1 15 Plate-Chain Adjuster 2
7 Hex. Nylock Nut 1 16 Flanged Hex. Nut M8 X 1.25 4
8 Chain Pad 1
9 CSK Screw M6X20 2
10 Bracket Complete - Chain Guard,

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CONTINENTAL GT

A1
8 11
7 6
Key Nos. 5 10 10
2, 3, (Qty. 2 Nos. 13 13 4
13 12
4 to 8) 2
9
A2 12

29 14
30 17 16
30
3
20 19 30 30
16 1 4
17 5
6
15 7
18 8

21 22
23
24
22
25 27 28
23
26 28
28

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Swing Arm End Cap, Bearing, Oil Seal & 15 Chain Tensioner Comp. - RH 1
Spacer Kit 1 16 Plate - Chain Adjuster 2
A2 Chain Adjuster Kit (RH and LH) 1 17 Flanged Hex. Nut M8X1.25 4
1 Swing Arm Sub Assembly 1
18 Flanged Hex. Bolt 1
2 Nylon Bush - Swing Arm 1
19 Spacer - Swing Arm 1
3 Inner Spacer - Swing Arm 1
20 Hex. Nut with Nylock M12 1
4 Needle Bearing (33 X 252 X 25) 2
21 Domed Bolt - 3/8"X40 1
5 Inner Race - Needle Bearing (IR20X25X26) 2
22 Spring Washer - 3/8” 2
6 Oil Seal - Swing Arm 2
23 Plain Washer (M10) 2
7 Spacer - Oil Seal Swing Arm 2
8 End Cap RH - Swing Arm 2 24 Hex. Nut 3/8” BSF 1

9 Rear Chain - Pad 1 25 Bracket - Plastic Chain Guard 1

10 Washer 2 26 Hex. Bolt 3/8” X 45 1
11 Hex Scew M6 X 16 2 27 Chain Guard - Plastic 1
12 Clip - Rear Disc Hose 3 28 Slotted Head Screw M6 X 13 3
13 Philips Pan Head Screw M6X6 3 29 Cover - ABS Modulator 1
14 Chain Tensioner Comp. - LH 1 30 Flanged Hexagonal Bolt M6 X 1 X 20 4

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.5 Rear Swing Arm
Bullet Classic EFI /
Bullet EFI
 Place the motorcycle on
its center stand, on a firm
and flat surface such
that the rear wheel is
about 4 inches (10 cms)
above the ground.

 Hold the Axle from the

left side. Hex Nut M16
Double End Spanner 24
 Loosen and remove hex
mm
nut on right side of the
swing arm.
 Remove wheel spindle
from left side.
 Gently release the brake
hose from the holding
clip in the swing arm.
 Remove the caliper
assembly by gently
pulling out from the
swing arm slot and
support the caliper
suitably.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.5 Rear Swing Arm
Bullet Classic EFI /
Bullet EFI
 Ensure the spacer is
removed and stored
carefully
 Gently pull rear wheel
towards the left so that
the hub becomes free
from lugs in the sprocket
 Slide out the Rear wheel
assembly from the swing
arm
 Remove the Hex bolt on Hex Bolt M 8
the other end of the
swing arm along with end Socket Spanner 13 mm
cups,spacer,celconbushes,
washer, hex nut.
 Gently remove the swing
arm assembly from the
frame.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.5 Rear Swing Arm
Bullet Classic EFI /
Bullet EFI
 Locate the swing arm
assembly from the
frame.

 Install the Hex bolt on

the other end of the Hex Nut M16
swing arm along with end Double End Spanner 24
cups, spacer, celcon mm
bushes, washer, hex nut.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.5 Rear Swing Arm
Continental GT
 Loosen the Hex bolt on
the other end of the
swing arm along with
needle bearings, oil
seals, spacers, end cups,
spacer swing arm, hex
nut.
 Gently remove the swing
arm assembly from the Index mark
frame.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
7.5 Rear Swing Arm
Continental GT
 Locate the swing arm
assembly to the frame.
 Install the Hex bolt on
the other end of the
swing arm along with
needle bearings, oil
seals, spacers, end cups,
spacer swing arm, hex
nut.

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SECTION 08 - ABS (ANTILOCK BRAKING SYSTEM)

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI - ANTILOCK BRAKE SYSTEM
6
5 2

3
8

5 7
1
9

2
5
2
10 5

12
11

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 ABS System 1 7 Brake Hose Assy-ABS To Rear Master Cylinder 1

1 Front Caliper 1 8 Master Cylinder Assy Comp -Rear 1
2 Copper Washer-Rear Disc 16 9 Rear Brake Switch 1
3 Brake Hose Assy-ABS To Front Caliper 1 10 Brake Hose Assy-ABS To Rear Caliper 1
4 Brake Hose Assy - ABS To Front Master Cylinder 1 11 Caliper Assy-Rear 1
5 Banjo Bolt-Rear Disc(Black) 7 12 ABS Modulator 1
6 Master Cylinder-Front 1

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BULLET EFI & CLASSIC MODELS - ABS MOUNTING TO FRAME

A1

3 2

7
8 6 5 14

5 13
12
6
7

9 11
10

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 ABS System 8 Bracket Assy - ABS & Cover 1

1 Clamp Brake Hose 1 9 Wheel Speed Sensor 1

2 Clamp Front Caliper Hose 1 10 Hex Button Head Screw M6 X 1 X 16 1

3 Hex Bolt M6 X 1 X 10 1 11 Engine Mounting Plate - Rear LH Black 1

4 Wire Strap 1 12 Engine Mtg Plate - Rear RH Black 1

5 Sleeve 2 13 Hex Button Head Screw M6 X 1 X 16 1

6 Rubber Grommet 2 14 ABS Modulator 1

7 Flanged Hex Bolt M6 X 1 X 20 1

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CONTINENTAL GT - ANTILOCK BRAKE SYSTEM

6
5 2 2
21 22
17

4 16

19
20

18 18

3 15
8

1 9

5
14 2
13 7
10
2
5

2
12
11

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 Abs System 1 12 Abs Modulator 1

1 Front Caliper 1 13 Brake Pad RH - Front Caliper 1
2 Copper Washer 16 14 Brake Pad LH - Front Caliper 1
3 Brake Hose Assy-Abs To Front Caliper 1 15 Reservoir (Threaded) - Rear 1
4 Brake Hose Assy -Abs To Front Master Cyl 1 16 Diaphragm 1
5 Banjo Bolt 7 17 Reservoir Cap 1
6 Master Cylinder-Front 1 18 Clip (Reservoir) 1
7 Brake Hose Assy-Abs To Rear Master Cyl 1 19 Reservoir Hose (Rubber) 2
8 Master Cylinder Assy Comp -Rear 1 20 Hex.Socket Button Head Screrw M6X1 2
9 Rear Brake Switch 1 21 Pad- Rear Disc 1
10 Brake Hose Assy-Abs To Rear Caliper 1 22 Pad-Piston Side - Rear Disc 1
11 Caliper Assy-Rear 1

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CONTINENTAL GT - ABS MOUNTING TO FRAME

2 5
3

A1

5 11
6
7 10
8
76 9
5

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

A1 ABS System 1 6 Sleeve 2

1 Flanged Hexoganal Bolt M6X1X10 3 7 Grommet 2

2 Clamp RH - Brake Hose 1 8 Bracket - ABS Modulator 1
3 Clamp LH - Brake Hose 1 9 Flanged Hex Bolt M8X20 2

4 Clamp Front - Brake Hose 1 10 Hex. Socket Button Head Screw M6X1x16 1
5 Flanged Hexoganal Bolt M6X1X20 2 11 Wheel Speed Sensor - ABS 1

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Anti-Lock Braking System (ABS) fitted in Royal Enfield motorcycles, is a safety system to help the front and rear
wheels maintain traction with the road surface in the event of sudden application of brakes by the rider at high speeds.
It helps prevent the brakes from “locking” the wheels which can potentially cause the motorcycle to skid and result in
loss of control and an accident.

Without ABS

With ABS

WORKING PRINCIPLE
During hard application of brakes, the sudden increase in the hydraulic force to the front and rear brakes are
controlled by a hydraulic pressure moderator which constantly reduces the excessive force on the hydraulic system
thereby ensuring the brake pads do not lock the brake discs. The moderator is controlled by an Electronic control
unit which not only receives real time inputs on the wheel speeds through sensors fitted near the wheel hubs but also
provides inputs to the valves in the moderator to regulate the hydraulic pressure such that the brake pads do not lock
the brake disc and cause the motorcycle to skid during emergency brake applications.

CAUTION:
While ABS assists in improved vehicle control during braking, decreased stopping distances on dry and graveled
surfaces, it may not be very effective in wet, snow covered, off road, conditions, loose gravel surfaces, hilly roads etc.,
since the traction of the wheel itself will be very minimal in these conditions.
As far as possible, all braking, including emergency braking should be done with the motorcycle upright and in a straight
motion. Avoid hard braking when banking heavily at great speeds.
Caution must be exercised by the rider for safe riding of the motorcycle and judge stopping distances
required, depending on the speed at which the motorcycle is travelling.
As soon as the ignition and engine stop switch are switched ‘ON’, the ABS sign will light up. The lamp
will remain ‘ON’ till the motorcycle attains a speed of 5 Kmph. (3MPH) and then switch ‘OFF’. This
indicates the ABS is working properly.
In the event the lamp does not switch ‘OFF’ and remains continuously ‘ON’ at higher speeds, it is recommended not to
drive the motorcycle and get the brake system inspected and corrected through a nearest authorized Royal Enfield
Distributor.

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8.1 LOCATION OF THE ABS SYSTEM PARTS

1. ABS INDICATOR

Bullet EFI and Classic EFI

 Located inside the small meter in the
head lamp casing alongside the EMS
MIL and low fuel warning lamp.

CONTINENTAL GT
 Located in the RPM meter in instrument
cluster

2. MODULATOR

Bullet EFI and Classic EFI

 Located inside the cover near throttle
body on the right side

CONTINENTAL GT
 Located above the centre stand on the
frame

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8.1 LOCATION OF THE ABS SYSTEM PARTS

3. ECU.
 Located adjacent to Modulator

4. FRONT BRAKE MASTER CYLINDER.

 Located on Handle bar RH side

5. FRONT WHEEL CALIPER.

 Located on the fork end LH side

6. WHEEL SPEED SENSOR - FRONT

 Located on the fork end LH side

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8.1 LOCATION OF THE ABS SYSTEM PARTS

7. TONER RING - FRONT WHEEL.

 Located on front Hub centre (below
brake disc)

8. REAR BRAKE MASTER CYLINDER

Bullet EFI and Classic EFI
 Located on the frame bottom on RH
side (underneath engine)

CONTINENTAL GT
 Located on the frame right side near
brake pedal

9. REAR HYDRAULIC FLUID RESERVOIR

 Located on the rear engine mounting
brackets of Frame.

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8.1 LOCATION OF THE ABS SYSTEM PARTS

10. REAR WHEEL CALIPER

 Located on swing arm LH side

11. WHEEL SPEED SENSOR - REAR

 Located on the rear caliper assembly
mounting bracket

12.TONER RING – REAR WHEEL

 Located on the rear hub left side below
the brake disc

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8.1 LOCATION OF THE ABS SYSTEM PARTS

BULLET EFI / BULLET CLASSIC EFI

CONTINENTAL GT

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CAUTION :
DO NOT REMOVE OR DISMANTLE ANY PART OF THE ABS SYSTEM - BRAKE HOSE CONNECTIONS, MODULATOR, ECU
ETC AS IS WILL NOT ONLY AFFECT THE BRAKING EFFICIENCY SEVERELY BUT WILL ALSO DEACTIVATE THE
MODULATOR AND THE ECU
DO NOT ATTEMPT TO REMOVE THE ECU OR THE ELECTRICAL CONNECTIONS FROM THE MODULATOR AS IT WILL
ERASE THE MEMORY AND THE PROGRAMME.
IF FOR ANY REASON THE BRAKE HOSES OR THE MODULATOR HAS TO BE SERVICED, THEN THE ENTIRE HYDRAULIC
FLUID SYSTEM BLEEDING HAS TO BE CARRIED OUT AND THE ECU HAS TO BE REPROGRAMMED.

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No. Instructions
8.2 ABS Modulator &
ECU
 Drain out hydraulic
brake fluid from the CAUTION:
front and rear reservoirs Brake fluid is extremely
and brake calipers by corrosive and hence please
loosening the bleeding take care not to spill on any
screws in the front and part of the motorcycle
rear calipers and gently
pumping the brakes.

 Remove the ABS cover

Hex Bolt: M6
from the RH side (Bullet
& Classic Models Only) Double end spanner:
by loosening 2 Hex bolts 10mm
on the sides.

 Loosen and remove the

4 banjo bolts holding 4
brake hoses to the
modulator.

 Ensure Ignition switch

and engine stop switch is
in OFF position.

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No. Instructions
8.2 ABS Modulator &
ECU
 Remove wiring coupler
to the ABS ECU and
gently pull out ECU.
 Remove 2 hex bolts on
the sides and 1 hex bolt Hex Bolt: M6
at the bottom, holding Double end spanner:
modulator to the mount- 10mm
ing bracket.

 Remove ABS assembly

from the bracket.

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No. Instructions
8.3 ABS Modulator &
ECU
 Locate ABS assembly to
the bracket.

 Install 2 hex bolts on the Hex Bolt: M6

sides and 1 hex bolt at
the bottom, holding Double end spanner:
modulator to the mount- 10mm
ing bracket
 Connect wiring coupler
to the ABS ECU and
gently locate out ECU.

 Ensure Ignition switch

and engine stop switch is
in OFF position.

 Locate and install the 4

banjo bolts holding 4
brake hoses to the
modulator.

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No. Instructions
8.3 ABS Modulator &
ECU
 Locate the ABS cover on
the RH side (Bullet & Hex Bolt: M6
Classic Models Only) by Double end spanner:
installing 2 Hex bolts on 10mm
the sides.

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No. Instructions
8.4 Brake Pad
Dismantling
 Remove the wooden
piece / card board sheet
in between the brake
pads.

 Remove the clip hanger

from the caliper
assembly by using
combination plier.

 Remove the pad pin

from the caliper
assembly by using
combination plier.

 Remove the worn out

brake pad from the
caliper assembly.

Pad Service
Limit 3.8mm

 Clean the caliper

assembly by dry / clean
cloth.

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No. Instructions
8.4 Brake Pad
Assembling

 Place the new brake pad

into caliper assembly as
shown.

 Insert the pad pin in

caliper assembly by
using combination plier.

 Insert the clip hanger in

caliper assembly.

 Place the wooden piece

/ card board sheet in
between the brake
pads.

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No. Instructions
8.5 Rear disc brake
pedal free play
Adjustment:
(Models: Classic
500/Bullet 500/
Conti-GT) Adjuster Location Master Cylinder

 The recommended
brake pedal travel is 7 to
11mm ( C5/B5), 4 to 7 mm
(GT)
Lock Nut Push Rod

 Loosen the lock nut in

Master cylinder push rod
assembly.

 Rotate the master

cylinder push rod anti-
clockwise to reduce
the rear brake pedal free
play.
NOTE :
Please Detach brake returns
spring from Master Cylinder
b e f o r e .p r o c e e d i n g

 Rotate the master (Applicable for only Classic

cylinder push rod 500/ Bullet 500 Models)
clockwise to increase the
rear brake pedal free Hex lock nut M8
play.
Double end spanner 13mm.

 After adjustment tighten

the lock nut in master NOTE :
cylinder push rod Please connect Rear Brake
assembly. pedal returns spring to
Master Cylinder.

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No. Instructions
8.6 Disc Brake Bleeding NOTE:
 Dust cap on the bleeder As these Euro IV Bikes are
screw to be removed fitted with ABS, the
from the Caliper Bleeding process
assembly. Connect the consumes more time since
the bleeding process has to
transparent plastic tube
start from master cylinder
with bleed screw and
to ABS and then to Brake
immerse it in a glass / Caliper which consumes
transparent plastic jar more time than usual
which is filled with clean bleeding time.
brake fluid.
 Ensure that the plastic
tube is below the fluid
surface throughout the
operation. This will
prevent atmospheric air
from getting sucked into
caliper unit.

 Fill the Master cylinder

with ‘Fresh brake fluid’
from a sealed container
till “MAX” level.

 Open the bleed screw to

½ a turn.

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 S. Aggregate to Assemble /
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No. Instructions
8.6 Disc Brake Bleeding NOTE :
 Fully press the brake Always tight top mounting
lever. bolt and then bottom
mounting bolt.
 After then tighten the
bleed screw. Check the entire system for
leakage before using the
 Now release the brake vehicle on road & also
lever. ensure tightening torque of
Bleed screw, Banjo bolt, Bolt
 Then gently stroke the clamps, screws and Caliper
lever until, the pressure mounting bolts.
is felt at lever to a
satisfactory limit and
Torque: 4 to 7 Nm
then tighten the bleed
screw.

Hex bolt M5
Ring Spanner 8 mm
Torque – 12 Nm

 Repeat the above steps

in a sequential manner WARNING :
until the fluid pressure is Wipe out Brake fluid which
felt in the brake lever. is spilled on the parts
thoroughly otherwise colour
parts may get fade.

 Relocate & tighten the

Master Cylinder assembly
CAUTION :
to the original location Don’t Mix DOT 4 & Above
of the handle bar and Brake Fluid together
tighten the Bolt clamp

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No. Instructions
8.7 Disassemble of
Master Cylinder
 Connect one end of a
lengthy tube to the
Caliper bleed screw and
the another end to a
container.

 Unscrew the bleed screw

Hex nut M7
by 1 – 2 full turns and
slowly pump the system Ring Spanner 11 mm
by actuating the Lever
until all the fluid is Hex nut M8
expelled, then tighten
the screw. Double end spanner 14 mm

 Remove the rear view

mirror.

 Disconnect the Brake

Switch coupler.

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No. Instructions
8.7 Disassemble of
Master Cylinder
 Disconnect the Brake
Hose by removing the
Banjo bolt and Washers.

 Remove the Nut – lever, CAUTION :

Bolt – lever and then
brake Lever. Clean the Cover thoroughly
before opening the Master
cylinder reservoir.

 Remove the Clamp bolts,

Clamp and the Master Hex Bolt M6
cylinder from the Ring Spanner 8mm
handlebar.
Hex Bolt M7
Spanner 12 mm

Hex Bolt M5
Ring Spanner 8mm
 Remove the wire from
the coupler by pressing
the projection in
terminal

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No. Instructions
8.8 Assembly Of
Master Cylinder
 Remove the Brake
Switch.

 Remove both Screws

and the top cover.

 Remove the Diaphragm

plate and Diaphragm
and empty out any
remaining brake fluid by
CAUTION :
using syringe.
Clean Master cylinder bore,
reservoir portion and Piston
with seals, with clean new
Brake fluid.
 Remove the Boot and Do not clean the rubber
the Circlip from the parts with petrol or any
Master cylinder body. other gasoline product or
water.

USE BRAKE FLUID

ONLY.

 Remove the Conical

spring (piston compression
spring).

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No. Instructions
8.8 Assembly Of Special Tool: Circlip
Master Cylinder removal tool
 Assemble the conical
spring (compression)
with the piston. Smear
the piston, seals and
cylinder bore with clean
brake fluid.
 Then assemble the
piston sub-assembly by
gently pressing into the
bore.

 Assemble the circlip into

the groove of the master
cylinder. Ensure that
circlip is seated inside
the groove properly.

 Assemble the rubber

CAUTION:
Boot.
Do not use tools with sharp
ends.

 Apply Silicon grease on

the Lever pivot hole and
on the Piston surface

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No. Instructions
8.8 Assembly Of
Master Cylinder
 Assemble the Brake
Switch.

 Ensure that the

projection of switch
body correctly seats in
the slot provided.
Assemble the Coupler
Terminal and ensure
proper locking of wires.

 Assemble the master

cylinder assembly on the
handle bar by using the
clamp with ‘ UP’ mark
facing upwards.

 Tighten the master

cylinder assy. clamp top Torque values:
Bolt - Clamp first and Bolt-lever 6 Nm
then tighten the bottom
Bolt. Nut-lever 6 Nm

Hex Bolt M5
Ring Spanner 8mm
 Assemble the Lever, Bolt
- lever and Nut-lever and
tighten.

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No. Instructions
8.8 Assembly Of
Master Cylinder
 Connect the Brake Hose
to Master cylinder by
Banjo bolt with new
Washers and then
tighten the Banjo bolt
Torque 3.5 KG-M.

 Connect the Switch

Hex Bolt M8
connectors properly.
Ring Spanner 13 mm
Torque 35 Nm

 Fill the brake fluid to the

Hex nut M8
Upper level mark and
bleed the system. Then Double end spanner 14 mm
assemble the Diaphragm, Torque 15 Nm
diaphragm plate and
Cover. Tighten screws
gently.
 Assemble the rear view
mirror.

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GENERAL INSTRUCTIONS – DISC BRAKE
 Check, monthly or every 2000 kms., the Brake fluid level through the Sight-glass whether it is above the
‘MINLINE’ mark. While checking, turn the handle bar straight, until the reservoir is horizontal.

 Never mix different types of brake fluids. (DOT 4 & ABOVE Together)

 Do not clean the rubber parts with petrol or any other gasoline product or water. Use clean brake fluid only.

 In case of water contamination of Brake fluid, drain the fluid completely, refill the system and bleed.

 Do not top up brake fluid above “Max” level to avoid front wheel binding problem

 Check periodically whether the Disc has been contaminated with oil, brake fluid or grease and clean contaminated
Disc with a high quality brake-degreasing agent.

 Always keep the disc clean and dry at all times for the brakes to work at peak efficiency.

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No. Instructions
8.9 Brake Caliper
 Disconnect the brake
hose by removing the
banjo bolt along with Hex bolt 12 mm
sealing washers at the
wheel caliper end.
 Gently pump the brake
lever till the hydraulic oil
is fully flushed out of the
master cylinder and the
hose.

 Loosen both the Caliper Hex Bolt 13 mm GT

mounting bolts on the
fork end and remove the Hex Bolt 12 mm C5/B5
caliper. Socket Spanner – 13mm/
12mm

8.10 Brake Pads Hex Bolt 13 mm GT

 Loosen both the Caliper Hex Bolt 12 mm C5/B5
mounting bolts on the
fork end and remove the Socket Spanner – 13mm/
caliper. 12mm

 Remove the Grub screw

on the brake caliper Screw 11 mm

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No. Instructions
8.10 Brake Pads
 Loosen and remove 2
hex socket head screws
from the caliper body Hex Bolt 13 mm GT
Hex Bolt 12 mm C5/B5
Socket Spanner – 13mm/
12mm

 Remove the brake pad

from Caliper Assembly.

 Remove the Pad

tensioner spring plate.

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8.11 Pistons & seals
from caliper
 Remove Mounting
Bracket from the Caliper CAUTION:
Assembly. Do not use high pressure air
or bring the nozzle too close
to the inlet. Place a shop
towel over the pistons to
prevent the pistons from
becoming projectiles.
Push the Dust seals and
Piston seals in and lift them
out using a blunt tool.
 Remove the Bellow &
Boot. Care should be taken to
avoid any damage on the
bore of the sliding surface.

 Position the caliper body

with the Pistons down
CAUTION:
and apply small squirts Enough care should be
of air pressure to the taken to avoid damages of
fluid inlet hole to remove the piston O.D. while
the Pistons. servicing / handling.
Remove the Bleed Screw

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No. Instructions
8.11 Pistons & seals in
caliper
 Coat clean brake fluid on
new Dust seals and
Piston seals and install
them in the sealgrooves
of the caliper body.

 Coat the caliper cylinders

and Pistons withSilicon
grease or clean brake
fluid and
Install the pistons into
the caliper body with the
dished end facing
inwards.

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No. Instructions
8.12 Brake pads

 Install the Pad tension

spring plate into the
Caliper body.

 Assemble Bleed screw

into caliper body.

 Assemble the Mounting

Bracket with caliper
Body.

 First install the pad near

to the piston and then
assemble other pad.

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No. Instructions
8.12 Brake pads

 Apply Silicon grease on

the Pin OD and then
assemble the Pin bolt by
pressingbrake pads into
caliper body.

 Mount the Caliper

assembly into Fork Torque 17 Nm
andtighten the
Mounting bolts.
Torque 25 Nm

 Tighten the Pin bolts

 Install the Grub screw
and tighten

 Connect the brake hose

to the caliper with New Torque 35 Nm
sealing copper washer
and then Tighten the
Banjo bolt.
 Fill the brake fluid and
bleed the hydraulic
brake system.

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ABS (ANTI-LOCK BRAKING SYSTEM) EFI TROUBLE SHOOTING CODES

S.No. P Codes for ABS Components monitored and malfunction type

1 5043 H Front wheel speed sensor Disconnection/ground Short/Uz Short

2 5042 H Front wheel speed sensor malfunction – Plausibility

3 5045 H Rear wheel speed sensor Disconnection/ground Short/Uz Short

4 5044 H Rear wheel speed sensor malfunction – Plausibility

5 5025 H Deviation between Wheel speeds (WSS_GENERIC)

6 5017 H Front Inlet Valve malfunction (EV)

7 5018 H Front Outlet Valve malfunction (AV)

8 5013 H Rear Inlet Valve malfunction (EV)

9 5014 H Rear Outlet Valve malfunction (AV)

10 5035 H Pump Motor Malfunction

11 5019 H Valve Relay malfunction (Failsafe relay)

12 5055 H ECU malfunction

13 5052 H Power Supply Malfunction (Low Voltage)

14 5053 H Power Supply Malfunction (High Voltage)

15 5122 H Varcode EEPROM ReadError

16 5223 H VarCode EEPROM Out Of Range

17 5331 H Front Wheel Pressure sensor ohmic fault

18 5332 H Front wheel pressure sensor offset/Test Pulse/POT fault

19 5333 H External Supply for Pressure sensor failure

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SECTION 09 - EVAP

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI

2
16

16 7
16
16
3 7
16
16 6
4
15
11
10 8 13
17 16 12
9
16 13
5
14

12
14
16

15

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Hose Purge Valve To Tank 1 10 Canister 1

2 Hose T Connector To Throttle Body 1 11 Hose Canister Vent 1
3 T Connector 1 12 Bush Pav 2
4 Hose T Connector To Canister 1 13 Hex.Socket Hd.Cap Screw,M6 X 20 2
5 Hose Purge To Canister 1 14 Grommet 2
6 Cable Clip Evap 2 15 Bracket Assy Canister Mtg 1
7 Adaptor Purge Valve LH 2 16 Wire Clip 11
8 Purge Valve 1 17 Hose T Connector To Purge Valve 1
9 Adaptor Purge Valve RH 1

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CONTINENTAL GT

3
11
8 10
9
1 5
6
5
2
7 11
10
9

5
5 12

19

18

5 14
5 5 13
16 15
17 5

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Bracket-Purge Valve 1 11 Hex.Socket Hd.Cap Screw,M6 X 20 2

2 Pan Head Screw M5 X 12 1 12 Hose Canister Vent 1
3 Cable Clip Evap 2 13 Canister Cover 1
4 Hose-Purge Valve To Tank(GT) 1 14 Hose- Purge Valve To Canister(GT) 1
5 Clip- Evap Hoses 10 15 Hose T-Connector To Canister(GT) 1
6 Hose-T-Connector To Throttle(GT) 1 16 T – Connector 1
7 Adaptor Purge Valve LH 2 17 Hose -Purge Valve To T-Connector(GT) 1
8 Canister Assy 1 18 Adaptor Purge Valve RH 1
9 Grommet 2 19 Purge Valve 1
10 Sleeve 2

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The Evaporative emission control system EVAP fitted in our motorcycles prevents gasoline vapors from escaping
into the atmosphere from the vent holes provided in the fuel tank cap.
As soon as the motorcycle is parked after riding or parked under the sun, the hot radiation from the engine / sunlight
causes the fuel in the tank to warm up and releases fuel vapors.
The EVAP system prevents these fuel vapors from escaping into the atmosphere and stored in a charcoal canister.
As soon as the engine is started, these vapours are purged from the canister, into the combustion chamber.

The system consists of a canister, purge valve, rubber hoses, connectors and a sealed fuel tank cap.

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The canister is connected to the fuel tank to trap all the fuel vapours that build up in the fuel tank .

LOCATION OF EVAP
Located behind swing arm in Bullet & Classic EFI models.

Located below Throttle body in Continental GT models.

PURGE VALVE
The purge valve is a mechanically controlled one way valve. When the engine is off, the purge valve is closed. When
the engine is started, the vacuum created in the suction port is used to open this one way valve and allow the vapors
to go into the inlet port.

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INSPECTION
Inspect rubber hoses and joints periodically for any cuts cracks or fractures. Replace if damaged.

Inspect Canister periodically for any damage to its body cuts or cracks.

Replace all rubber hoses and connectors every 12,000 Kms.

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 S. Aggregate to Dismantle/
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
Canister
Bullet Classic EFI /
Bullet EFI
 Remove 2 bolts mounted
on the Piece mudguard.
 Remove the canister
along with the tubes and
connectors.

Canister
Continental GT

 Remove 2 bolts mounted

on the Frame additional
bracket.
 Remove the canister
along with the tubes and
connectors.

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 S. Aggregate to Assemble/
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No. Instructions
Canister
Bullet Classic EFI /
Bullet EFI
 Locate Cannister in the
piece mudguard bracket
such that it can be
tightened with 2 hex
bolts.
 Tighten the 2 bolts.

Canister
Continental GT

 Locate Cannister in the

bracket in the frame
below throttle body
such that it can be
tightened with 2 hex
bolts.
 Tighten the 2 bolts.

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SECTION 10 - ENGINE MANAGEMENT SYSTEM (EMS)

Royal Enfield Motorcycles being supplied to the European Union are fitted with an intelligent Engine Management
System (EMS).
The EMS consists of an Electronic Control Unit (ECU) which constantly receives inputs like engine temperature,
ambient temperature, throttle position, manifold air pressure, exhaust emissions through the various sensors
provided to optimize the air fuel ratio AND crank position (from the crank position sensor) in relation to the engine
RPM to optimize the ignition advance for proper combustion of the air fuel mixture.
This is very essential for:
- Compliance with EURO IV regulation related to exhaust emissions
- Optimum fuel efficiency and power output
- Excellent cold start ability and sustained high speed drive ability.

FUNCTIONAL DIAGRAM OF THE EMS

Provides
inputs TO
ECU.
Has a two
way
communi-
cation with
ECU

Receives
inputs from
ECU

In addition to optimizing engine performance, the ECU also has an inbuilt memory by which any EMS related
malfunctions will get stored and help diagnose the fault accurately.
There is also an inbuilt safety system, which, in the event of the motorcycle’s banking angle is below 60o OR is involved
in an accident causing the motorcycle to fall over on either of its sides with the gears engaged and the engine running,
both the fuel supply and ignition will be cut off to stop the engine and prevent any further damage from being caused.

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SPECIFICATIONS / FUNCTIONS OF THE VARIOUS EMS PARTS
1. ELECTRONIC CONTROL UNIT (ECU)
The Electronic Control Unit (ECU) is located inside the Electricals box on the Left side (Bullet EFI/ Classic EFI models)
and under the seat (Continental GT models).

SPECIFICATION
Operating Voltage: 8 – 16 V
Sensor Supply Voltage: 5 V
Operating temperature: –10ºC to + 60ºC
Storage Temperature: –20ºC to + 80ºC

The ECU consists of a microprocessor with two memories Flash Memory and E2 PROM.
Flash memory is an exclusive recording unit. It collects different inputs from various sensors and calculates optimized
values and provides the outputs to the respective controlling devices.
E2PROM is an abbreviation for Electronically Erasable Programmable Read Only Memory. This memory records
information related to performance of the various sensors in the EMS on a real time basis AND also records any sensor
failures if it occurs during operation of the motorcycle.
The main advantage of E2PROM is it records data, even when the motorcycle’s electrical system is switched OFF.
This will help in diagnosing the motorcycle performance and also to view the history and defect codes, whenever the
Royal Enfield NACS II diagnostic tool is connected to the socket in the wiring harness of the motorcycle.
Once the defect is diagnosed and corrected, the history of the defect can be erased using the Royal Enfield NACS II
diagnostic tool.

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ECU LAYOUT ECU PIN DETAILS
Pin No. Name Function
1 IGP Ignition Power
2 LG Logic Ground
3 HEGO HEGO Sensor
4. SG Sensor Ground
5 TH Throttle Position Sensor
6 VCC Sensor Power Output (+SV)
7 - -
8 FP Fuel Pump
9 PG1 Power Ground1
10 PG2 Power Ground2
11 IG Ignition Coil
12 CRK-P Crank Pulse Sensor
13 - -
14 TA Air Temperature
15 TEST Test Switch
16 INJ Injector
17 VSP Vehicle Speed Sensor
18 - -
19 - -
20 - -
21 - -
22 MIL Multi Indicator Lamp
23 CRK-M Crank Pulse Sensor GND
24 TW Engine Temp. Sensor
25 SSTAND Side Stand Switch
26 ROLL Roll Sensor
27 PM Manifold Pressure Sensor
28 EXAJ Exhaust Air Injection
29 NLSW Neutral Switch
30 K-LINE Diagnostic Tool
31 - -
32 - -
33 HEGO HT HEGO Sensor Heater

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2. CRANK POSITION SENSOR
The crank position sensor sends an alternating voltage signal to the powertrain control module, which is used to
determine engine speed and ignition timing. Thus the speed of the engine is instantly known by the ECU.

SPECIFICATION
Output Voltage: 3 - 5 V AC.
Resistance : 200+20 Ω

It provides an alternating electrical pulse to the ECU, to determine crankshaft speed and TDC position by scanning
the 17 pips and 1 long gap between 2 particular pips on the rotor. This input helps the ECU to optimize both fuel
injection as well as Ignition advance required to suit the crankshaft rotation speed (RPM).
In the event the throttle is held wide open with gears in neutral, leading to crankshaft speed above 5500 RPM, the
high frequency electrical pulses from the crank position sensor will prompt the ECU to restrict fuel supply so that the
crank speed reduces below 5000 RPM. This is a safety aspect to prevent damage to moving engine parts.

3. ENGINE TEMPERATURE SENSOR

The engine temperature sensor (EOT) is located on the cylinder head, below the inlet manifold on the oil passage.

SPECIFICATION
Operating Temperature: -55°C to + 250°C
Resistance:25deg (10K Ω) 5% and Resistance at 80deg (1.63K Ω) 5%
Sensor Supply Voltage: 5V

It senses the oil temperature and provides the input to the ECU on a real time basis. The ECU can then determine the
fuel injector operating time to provide the required amount of vaporized fuel into the combustion chamber for
optimum performance of the motorcycle and also to meet the emission norms.

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4. HEGO SENSOR ( O2/LAMBDA SENSOR)
The HEGO sensor is located on the exhaust down pipe, just after the cylinder head.

SPECIFICATION
Operating Voltage : 16V (Max)
Operating temperature: 600ºC - 950ºC

It detects residual oxygen in the exhaust gases versus the amount of oxygen in the atmosphere and provides the
data on a real time basis to the ECU based on which the fuel injection is metered continuously to control exhaust
emissions and for optimum performance of the motorcycle.

5. EXHAUST AIR INJECTION UNIT (SOLENOID)

The exhaust air injection unit (EXAI) is located underneath the fuel tank.

SPECIFICATION
Operating voltage : 10 V to 14.5 V
Operating Temperature: - 20°C to +120°C

In addition to the Hego sensor, the EXAI gets inputs from the ECU to supply filtered air into the exhaust end of the
cylinder head, primarily during idling RPM so as to meet exhaust emission specifications.

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6. THROTTLE BODY
The throttle body is located below the fuel tank, between the intake side of the cylinder head & the air filter assembly.

SPECIFICATION
Operating Voltage: 5 V.
Out Put Voltage: 0 – 5V.
Throttle Angle : 0 – 80º
Resistance Maximum: 5 K Ω
Out Put at Idling: 0.6+0.2V.
Operating Temperature: –20ºC to +80ºC

It consists of a throttle plate (butterfly valve) to regulate the airflow into the cylinder head depending on the throttle
opening and a manual Bi Starter which helps control idling RPM in extreme cold conditions.
The throttle body also has a throttle position sensor (TPS) and manifold absolute pressure sensor (MAP).

7. THROTTLE POSITION SENSOR (TPS)

Throttle Position Sensor (TPS) is located on the throttle body at the end of the butterfly valve spindle to monitor the
position of the butterfly valve.

SPECIFICATION
Max Resistance : 5 K Ω
Operating Temp : - 20°C to +80°C
Supply Voltage : 5 V

The sensor consists of a potentiometer and provides a variable resistance depending upon the position of the
butterfly valve to the ECU. This helps the ECU to regulate the fuel injector opening duration to provide the required
amount of vaporized fuel into the combustion chamber for optimum performance of the motorcycle.

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8. MANIFOLD ABSOLUTE PRESSURE SENSOR (MAP)
The Manifold Absolute Pressure Sensor (MAP) is located on top of the throttle Body.

SPECIFICATION
Operating Temperature: -20°C to +80°C
Supply Voltage: 5 V

The MAP sensor monitors the manifold pressure at the intake end and provides data to the ECU on a real time basis.
This helps the ECU to calculate the air density and the air inflow rate and determines the fuel injector opening duration
to provide the required amount of vaporized fuel into the combustion chamber for optimum performance of the
motorcycle.

9. AMBIENT AIR (TA) SENSOR

The TA sensor is located on the rear side of the filter box assembly in Bullet EFI / Classic EFI models and on the outlet
pipe of the air filter housing in Continental GT models.

SPECIFICATION
Operating Temperature: -30°C to +120°C
Supply Voltage: 5 V+0.5 V

The ambient temperature input is provided to the ECU on a real time basis, based on which the ECU determines the
fuel injector operating time to provide the required amount of vaporized fuel into the combustion chamber for
optimum performance of the motorcycle.

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10. FUEL PUMP ASSEMBLY
The fuel pump is located on the left side bottom of the fuel tank and submerged in the fuel so that it cannot ignite itself
due to any electrical short circuits. The fuel pump has an inbuilt micro filter which helps to filter even the minute dust
particles that may come in the fuel.

SPECIFICATION
Operating Voltage: 6 V to 15 V
Operating Temperature: -15°C to +60°C
Fuel Pressure: 294 Kpa

As soon as the Ignition switch and the engine kill switch are in ON position, the fuel pump creates a positive pressure
of 294KPa in the fuel line and up to the injector. The fuel pump operation is determined by the ECU so that there is no
excessive pressure in the fuel system to prevent damage to the fuel injector, fuel hose. Any excess pressure is bypassed
back into the fuel tank.

11. FUEL INJECTOR

The fuel injector is located at an angle on the intake side of the cylinder head so as to maximize fuel spray and minimize
wall wetting, for optimum performance of the motorcycle.

SPECIFICATION Injector

Operating Voltage : 10 V to 16 V
Operating Temperature : -30°C to +120°C
Fuel Pressure : 343 Kpa
Resistance : 10.3 +0.5 Ohms

The Fuel Injector is a solenoid operated electromagnetic valve, which enables the pressurized fuel delivered by the
fuel pump, to be atomized and sprayed into the cylinder head combustion chamber.
The fuel injector operation and duration to deliver vaporized fuel is controlled by the ECU based on the critical
operating inputs received from the crank position sensor, EOT sensor, ambient air temperature sensor, throttle
position sensor, manifold pressure sensor and HEGO sensor.

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12. EFI ECU POWER & SIDE STAND RELAYS
There are two identical relays located inside the Electricals box LH side (on Bullet EFI & Classic EFI models) and on the
battery bracket inside the LH panel (on Continental GT models).

SPECIFICATION
Operating Voltage : 10 V to 16 V
Operating Temp : - 30 ° C to + 120 ° C
Fuel Pressure : 343 Kpa
Resistance : 10.3+0.5 Ohms

The EFI ECU Power relay supports functioning of the ECU and fuel pump. The Side stand relay provides the inputs
regarding the position of the side stand to the ECU. In the event the side stand is NOT retracted and the motorcycle
is attempted to be started, it signals the ECU which cuts off the fuel supply thus preventing the engine from starting.

13. ROLLOVER SENSOR

The rollover sensor is located on the frame under the seat.

SPECIFICATION
Operating voltage : 10 V to 14.5 V
Operating Temp : - 20 ° C to + 120 ° C

The rollover sensor, also known as a “banking” sensor, is a safety feature. If the banking angle of the motorcycle goes
below 60o OR in the event of an accident causing the motorcycle to fall over on either of its sides with the engine
running, the rollover sensor will “command” the ECU to cut off both the fuel supply and ignition, thus stalling the
engine to prevent any further damage from being caused by the engine that may be running with a stuck open throttle
and the gears engaged.
To re activate the system, the motorcycle should be made upright in its centre stand position, the ignition switch and
stop switch must be switched OFF and switched back ON after a few seconds. This will help to RESET the rollover
sensor.

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14. MALFUNCTION INDICATOR LAMP (MIL)
Malfunction Indicator Lamp (MIL) is located in the small meter on the Headlamp casing

SPECIFICATION
Operating Voltage :

When both the Ignition & Engine kill switch is “ON” and after vehicle is started, MIL will glow for few seconds and switch
OFF, this indicates that all the functions of EMS are functioning correctly.
In the event of any malfunction the MIL will glow continuously. The EMS should be checked using either the test pin
method OR the Royal Enfield NACS II diagnostic tool connected to the socket in the wiring harness of the motorcycle.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
10.1 Electronic Control
Unit (ECU)
A. Bullet EFI /
CAUTION:
Bullet Classic EFI
 Ensure both Ignition
 The ECU is located inside and Engine kill switch
the Electricals Box on the are in OFF position
LH side. before disconnecting
ECU from the wiring
 Ensure Ignition switch harness.
and stop switch are in
 DO NOT disconnect
OFF position. Battery with the
 Unlock the Electricals Ignition switch/ Kill
box lid. switch in ON position
and the ECU is
 Gently pull out the ECU connected.
from its rubber housing.  Ensure ECU is not
 Gently release lock and stored near any
Magnetic substances,
disconnect the wiring wet surfaces, direct
coupler from the ECU. sunlight and hot areas
as it will damage the
 Remove ECU ECU.

B. Continental GT
 The ECU is located under
the Fuel tank.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Unlock side panel LH and
remove the panel LH.
 Gently pull seat latch
cable to release seat and
remove seat.
 Gently pull out the ECU
from the rubber housing
located in the frame.
 Gently release lock and
disconnect the wiring
coupler from the ECU.

 Remove ECU.

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 S. Aggregate to Dismantle /
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No. Instructions
10.2 Crank position
sensor
 The Crank position
sensor is located inside CAUTION:
the cover RH of the  Ensure stator coupler is
engine assembly. disconnected before
 Drain engine oil from the removing cover RH.
engine.  Gently tap on the tabs
 Ensure Ignition switch provided in the front
and stop switch are in and rear of Cover RH to
OFF position. release the cover from
 Disconnect Magneto the crankcase.
wiring coupler from the
electrical harness.
 Loosen and remove 2
Hex Flange Bolt M6 X 1 X
85 from cover RH front.
 Loosen and remove 7
Hex Flange Bolt M6 X 1 X
70 from cover RH, top,
centre and bottom.
 Loosen and remove 1
Hex Flange Bolt M6 X 1 X
45 from cover RH rear.
 It may be necessary to
gently tap and remove
cover RH as the magnetic
forces in the rotor can be
acting on the stator and
making it difficult to
remove.
 Remove gasket.
 Remove 2 Hex Flange
Bolt M5 X 0.8 X 16,
holding Pulsar coil to
cover RH inside.
 Remove 3 Hex Socket
Head Cap Screw M5 X 30,
holding stator coil to
cover RH inside.

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 S. Aggregate to Dismantle /
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No. Instructions
10.3 Engine
Temperature
Sensor
Deep Groove Socket bit:
 The Engine temperature 17mm
sensor is located on the
cylinder head right side,
below the inlet manifold.
 Ensure Ignition switch
and stop switch are in
OFF position Disconnect
wiring harness coupler
from the sensor.
 Gently Loosen engine
temperature sensor and
remove along with ‘O’
ring.

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 S. Aggregate to Dismantle /
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No. Instructions
10.4 Hego (Lambda or
O2) Sensor
 The Hego sensor is
assembled on the inner Deep Groove Socket:
side of the exhaust 21mm
down pipe near the
cylinder head.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Disconnect wiring
harness coupler from
the sensor.
 Loosen Hego sensor and
remove along with
copper washer from the
exhaust down pipe.

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No. Instructions
10.5 Exhaust Air
Injection Unit (EXAI
Solenoid)
 The EXAI Solenoid is Gland Nut Double end
located on the frame spanner: 16mm
under the fuel tank
along with the reed Soc Hd Cap Screw: M5X20
valve. Allen Key 4mm
 Ensure Ignition switch
and stop switch are in Hex Screw M6 X 16
OFF position. Socket spanner: 8mm
 Remove Fuel tank as
described in section 2
Fuel tank.
 Disconnect wiring
harness coupler from
the EXAI solenoid.
 Release the 2 clips on the
Inlet and outlet pipes
connected to the EXAI
solenoid, and dis-
connect the pipes.

 Loosen Gland nut at

cylinder head end and
disconnect braided
hose connecting reed
valve to cylinder head.
 Remove the 2 Hex
Screws holding the reed
valve mounting bracket
to frame and remove
along with EXAI
solenoid.

 Remove socket head cap NOTE:

screw holding the EXAI
solenoid to the reed Ensure spacer between the
EXAI solenoid. & bracket is
valve bracket.
removed.

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No. Instructions
10.6 Throttle Body
 The throttle body is
located between the
cylinder head inlet and
the air filter outlet hose.
 Ensure Ignition switch
and stop switch are in
OFF position.

 Disconnect TPS and

MAP wiring couplers.

 Slacken the locknuts on

the adjusters and remove
throttle cables from the
throttle body. - Adjuster Nuts
 Disconnect rubber hose Double end spanner:
connecting throttle 12mm
body to the EVAP canister. - Hose clip screws: Flat
 Disconnect manual Bi screw driver
Starter cable from
throttle body by
loosening and removing
the plastic nut on LH
side.
 Loosen hose clip on air
NOTE:
inlet rubber hose.
 Loosen hose clip on The throttle position sensor
Adaptor between (TPS) and Manifold
throttle body and Absolute Pressure Sensor
cylinder head. (MAP) are not serviceable
and hence should not be
 Remove throttle body removed from the throttle
by gently sliding it out of body.
the inlet bellow and
adaptor.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
10.7 Ambient Air (TA)
Sensor
A. Bullet & Classic
EFI Models
 The TA sensor is
assembled behind the
Filter box assembly and
can be removed only
after removing the air
filter housing from the
frame (Refer section 5.2
Air filter.)
 Ensure Ignition switch
and stop switch are in
OFF position.
 Disconnect the wiring
coupler from the TA
sensor.
 Loosen and remove 2
Hex Soc Hd cap screws,
holding TA sensor to
Filter Box Assembly.
 Remove TA sensor with
gasket.

B. Continental GT Hex Soc Hd Cap Screws:

Model M5 X 20
 The TA sensor is assembled
on the pipe outlet bet- Allen Key: 4mm
ween air filter housing
and Throttle body.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Remove seat assembly
(Refer section 5.4)
 Disconnect the wiring Philips head screws
coupler from the TA
sensor. Philips Screw driver
 Using a long reach Philips
head screw driver,
loosen and remove the 2
screws, holding TA
sensor to pipe outlet.
 Remove TA sensor along
with gasket, from pipe
outlet.

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No. Instructions
10.8 Fuel Pump
Assembly
 The fuel pump assembly
is located inside the fuel CAUTION:
tank at the left side, rear  Store fuel in a tight
bottom. sealed container in a
well ventilated, cool
 Ensure Ignition switch and dry place.
and stop switch are in
OFF position.  Do not smoke or allow
open flame or sparks in
 Remove Seat assembly the vicinity.
as described in section
5.4 for seat dismantling.
NOTE:
 Remove fuel tank as
described in section Ensure Ignition switch and
engine kill switch are in OFF
5.3 for Fuel tank
position
dismantling.
Drain fuel completely from
 Loosen & remove 5 Hex fuel tank before removing
Socket Button Head Cap fuel pump.
Screws along with the
copper & fibre washers.
 Remove clamp plate. Hex Soc Button Hd Cap
Screws: M6 X 12
 Pull out fuel pump from
Socket spanner: 8mm
the fuel tank.
 Take care to remove the
O ring from the fuel tank.

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No. Instructions
10.9 Fuel Injector
 The fuel injector is
assembled on the inlet
side of cylinder head Hex U nut: M6 X 1
below the fuel tank. Ring spanner: 8mm
 Ensure Ignition switch
and stop switch are in
OFF position.
 Remove Seat assembly
as described in section
5.4 for Seat dismantling.
 Remove fuel tank as
described in section
5.3 for Fuel tank
dismantling.
 Disconnect the wiring
coupler from the fuel
injector.
 Loosen worm clip on the
inlet fuel hose and
remove fuel hose from
cap injector assembly.
 Remove hex nut from
top of injector cap
assembly and remove
injector cap along with
“O” ring.
 Remove the spacer from
the stud.
 Gently pull out the
Injector from the
cylinder head.

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No. Instructions
10.10 EFI ECU Power &
Side Stand Relays
A. Bullet EFI &
Classic EFI Models
 Two identical relays are
located inside the
electricals box LH.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Gently pull out the relays
from their sockets to
remove.

B. Continental GT
 Two identical relays are
located near the battery.
 Located in a rubber
holder on the side of the
battery carrier.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Remove side panel LH.
 Gently pull out relay
from the rubber holder
and electrical socket.

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No. Instructions
10.11 Roll Over Sensor
 Located below the seat
on the frame.
Hex Soc Hd Screw: M6
 Ensure Ignition switch
and engine stop switch Allen Key: 5mm
are in OFF position.

 Disconnect the wiring

coupler from the sensor.
 Loosen and remove the
hex socket screw holding
the sensor to the frame
and remove the sensor.

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No. Instructions
10.12 Malfunction
Indicator Lamp
A. Bullet EFI &
Classic EFI Models
 Located in the small
meter on Headlamp
casing which also has the
low fuel warning and
ABS indication.
 Ensure Ignition switch
and engine stop switch
are in OFF position.
 Disconnect the wiring
couplers from the meter.
 Gently push the meter
upwards from below to
release it from the
rubber ring.
 There are no serviceable
parts in the meter.

B. Continental GT
 Located in the RPM
meter in the instrument
cluster.
 Ensure Ignition switch
and engine stop switch
are in OFF position.
 The instrument cluster
does not have any
individual serviceable
parts.

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 S. Aggregate to Assemble /
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No. Instructions
10.13 Electronic Control
Unit (ECU)
A. Bullet EFI &
Classic EFI
 Locate ECU inside the CAUTION:
Electricals box on LH
side.  Ensure both Ignition
and Engine kill switch are
 Connect the wiring in OFF position before
coupler on the ECU and Connecting ECU into
gently lock. the wiring harness.
 Gently push the ECU on  DO NOT disconnect
its rubber housing. Battery with the Ignition
 Lock the Electricals box switch/ Kill switch in ON
lid. position and the ECU is
connected.
 Ensure Ignition switch
and stop switch are in  Ensure ECU is not
OFF position. stored near any
Magnetic substances,
wet surfaces, direct
sunlight and hot areas
as it will damage the ECU.
B. Continental GT
 Locate ECU under the
Fuel tank.
 Connect the wiring
coupler on the ECU and
gently lock.
 Gently push the ECU on
its rubber housing
located in the frame.
 The ECU is located under
the seat.
 Locate seat on the frame
and push it for proper
seating.
 Locate the side panel LH
and lock side panel LH.

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No. Instructions
10.14 Crank position
sensor

 Locate Crank position

sensor inside the cover
RH of the engine
assembly. CAUTION:
 Install 3 Hex Socket Head  Ensure stator coupler
Cap Screw M5 X 30, on is disconnected before
stator coil to cover RH removing cover RH.
inside.  Gently tap on the tabs
 Install 2 Hex Flange Bolt provided in the front
M5 X 0.8 X 16, on Pulsar and rear of Cover RH to
coil to cover RH inside release the cover from
the crankcase.
 Locate gasket.
 Install and tighten 1 Hex
Flange Bolt M6 X 1 X 45
on cover RH rear
 Install and tighten 7 Hex
Flange Bolt M6 X 1 X 70
on cover RH, top, centre
and bottom.
 Install and tighten 2 Hex
Flange Bolt M6 X 1 X 85
on cover RH front.
 Connect Magneto wiring
coupler in the electrical
harness.
 Fill engine oil.

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No. Instructions
10.15 Engine
Temperature
Sensor
Deep Groove Socket bit:
 Locate engine 17mm
temperature sensor
along with ‘O’ ring on the
cylinder head right side
below the inlet manifold.
 Ensure Ignition switch
and stop switch are in
OFF position, Connect
wiring harness coupler
on the sensor.

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No. Instructions
10.16 Hego (Lambda or
O2) Sensor
 Locate Hego sensor
along with copper Deep Groove Socket:
washer on the exhaust 21mm
down pipe near the
cylinder head.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Connect wiring harness
coupler on the sensor.

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No. Instructions
10.17 Exhaust Air
Injection Unit (EXAI
Solenoid)
 Locate socket head cap
screw on the EXAI Gland Nut
solenoid to the reed Double end spanner:
valve bracket. 16mm
Soc Hd Cap Screw: M5X20
 Install the 2 Hex Screws
on the reed valve Allen Key 4mm
mounting bracket to Hex Screw M6 X 16
frame.
Socket spanner: 8mm
 Locate EXAI Solenoid on
the frame under the fuel
tank along with the reed
valve.

 Install Gland nut at

cylinder head end and
connect braided hose
connecting reed valve to
cylinder head.

 Connect 2 clips on the

Inlet and outlet pipes NOTE:
connected to the EXAI
Ensure spacer between the
solenoid.
EXAI solenoid. & bracket is
removed.
 Ensure Ignition switch
and stop switch are in
OFF position, Connect
wiring harness coupler
in the EXAI solenoid.

 Assemble Fuel tank as

described in section 2
Fuel tank.

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No. Instructions
10.18 Throttle Body

 Locate throttle body

between the cylinder
head inlet and air filter
outlet house.
 Gently slide throttle
body on the inlet bellow
and adaptor.
 Locate hose clip on
Adaptor between
throttle body and cylinder
head.
 Locate hose clip on air
inlet rubber hose.
 Connect manual Bi
Starter cable on throttle
body by tightening and
locating the plastic nut
on LH side.
 Connect rubber hose
from throttle body to - Adjuster Nuts
the EVAP canister. Double end spanner:
 Locate the locknuts on 12mm
the adjusters and locate - Hose clip screws: Flat
throttle cables on the screw driver
throttle body.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Connect TPS and MAP
wiring couplers. NOTE:
The throttle position sensor
(TPS) and Manifold Absolute
Pressure Sensor (MAP) are
not serviceable and hence
should not be removed
from the throttle body.

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No. Instructions
10.19 Ambient Air (TA)
Sensor
A. Bullet & Classic
EFI Models
 Locate TA sensor along
with gasket on pipe
outlet, behind the filter
box assembly.
 Install 2 Hex Soc Hd cap
Hex Soc Hd Cap Screws:
screws, on TA sensor to
M5 X 20
Filter Box Assembly.
Allen Key: 4mm
 Ensure Ignition switch
and stop switch are in
OFF position.
 Connect the wiring
coupler on the TA sensor.

B. Continental GT
Model
 Locate TA sensor along
with gasket on pipe
outlet between air filter
housing and throttle
body.
 Using a long reach Philips
head screw driver, Install Philips head screws
2 screws, holding TA Philips Screw driver
sensor to pipe outlet.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Connect the wiring
coupler in the TA sensor.
 Assemble seat assembly
(Refer section 5.4)

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10.20 Fuel Pump
Assembly

 Locate the O ring in the

fuel tank.
NOTE:
Ensure Ignition switch and
 Locate fuel pump engine kill switch are in OFF
assembly inside the fuel position.
tank at left side.

 Install clamp plate.

 Install 5 Hex Socket Hex Soc Button Hd Cap

Button Head Cap Screws
Screws: M6 X 12
along with the copper &
fibre washers. Socket spanner: 8mm

 Install fuel tank as

described in section 5.3
for Fuel tank assembly.

 Assemble Seat assembly

as described in section
5.4 for Seat assembly.

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10.21 Fuel Injector

 Locate fuel Injector on

the inlet side of the Hex U nut: M6 X 1
cylinder head below the
fuel tank. Ring spanner: 8mm

 Locate the spacer in the

stud.
 Locate hex nut from top
of injector cap assembly
and place injector cap
along with “O” ring.
 Locate worm clip on the
inlet fuel hose and locate
fuel hose on cap injector
assembly.
 Ensure Ignition switch
and stop switch are in
OFF position.
 Connect the wiring
coupler from the fuel
injector.
 Install fuel tank as
described in section 5.3
for Fuel tank assembly.
 Assemble Seat assembly
as described in section
5.4 for Seat assembly.

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No. Instructions
10.22 EFI ECU Power &
Side Stand Relays
A. Bullet EFI &
Classic EFI Models:

 Ensure Ignition switch

and stop switch are in
OFF position.
 Gently push the two
identical relays in their
sockets inside the
electrical box LH.

B. Continental GT
 Ensure Ignition switch
and stop switch are in
OFF position.
 Gently push the two
identical relays in the
rubber holder and
electrical socket.
 Locate in a rubber holder
on the side of the battery
carrier.
 Locate side panel LH.

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No. Instructions
10.22 Roll Over Sensor

 Locate the hex socket

Hex Soc Hd Screw: M6
screw on the sensor to
the frame and install the Allen Key: 5mm
sensor which is located
below the seat on the
frame.

 Connect the wiring

coupler from the sensor.

 Ensure Ignition switch

and engine stop switch
are in OFF position.

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10.23 Malfunction
Indicator Lamp
A. Bullet EFI &
Classic EFI Models
 Gently push the meter
downwards from top to
locate it on the rubber
ring.

 Ensure Ignition switch

and engine stop switch
are in OFF position.

 Connect the wiring

couplers from the meter.

 There are no serviceable

parts in the meter.

B. Continental GT
 Ensure Ignition switch
and engine stop switch
are in OFF position.

 Locate the RPM meter in

the instrument cluster.

 The instrument cluster

does not have any
individual serviceable
parts.

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EMS FAULT DIAGNOSIS & TROUBLE SHOOTING
NOTE:
 During diagnosis the motorcycle should be parked in its center stand, the side stand in fully retracted position
and with the gears in neutral .
 The battery should be in fully charged and proper working condition.
 There should be no external electrical sources or interferences near the motorcycle.

TYPES OF DIAGNOSIS
There are three levels of identifying a malfunction in the ECU or the sensors.

LEVEL 1 VISUAL
As soon as the ignition switch, engine stop switch are in ON position and the side stand is in fully retracted position,
the MIL will glow and will switch OFF after a few seconds after the engine is started. This indicates the EMS system is
in its auto diagnostic mode and the EMS is working perfectly.
In the event the MIL glows continuously and does not switch off, it indicates a malfunction in the EMS.

LEVEL 2 TEST PIN

In the event the MIL is continuously ON and does not switch OFF, the test pin method will help narrow down to the
sensor / electrical connection that caused the malfunction.

LEVEL 3 GENERIC SCAN TOOL (NACS II DIAGNOSTIC TOOL)

A generic scan tool supplied by Royal Enfield will help identify the exact cause of the malfunction in the EMS, when
connected between the motorcycle and a computer.
The tool will take inputs from the ECU and provide to the computer to display the defect code that will help identify
the specific sensor/connections.
In addition the generic scan tool can also help download the history of the vital parameters of the EMS, engine
performance and earlier defects for detailed analysis and records.
The generic scan tool will also be able to erase previous defects after the same has been rectified.

METHOD OF CHECKING
LEVEL 1 VISUAL
 Switch OFF the ignition and engine stop switch.
 Check for any loose coupler connections at the sensor end. Correct loose connections if any.
 Switch ON ignition and engine stop switch. Ensure side stand is fully retracted.
 Check for MIL Indication in the cluster/Console.
- Start the engine.
- Allow engine to run in idling RPM for about 30 seconds and switch off engine.
- Repeat the above process for 2 more times.

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 - Ensure MIL Indications goes off after above method.
- This will help to recalibrate the MIL and store the error code in the ECU.
 If in case the defect is not eliminated and the MIL glows continuously, proceed to level 2 test pin method to
resolve the defect.

LEVEL 2 TEST PIN METHOD

An open single pole connector is provided close to the UCE.

 Connect a piece of wire to this connector and suitably ground it to the motorcycle body.
 Switch ON ignition and engine stop switch and observe the MIL keenly for a series of short and long blinks at
different intervals, to identify the defective sensor / wiring connection as detailed in the table below,

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MIL BLINK CODES DESCRIPTION

MIL BLINK MALFUNCATION INDICATION

MIL will glow continuous. Engine will start but not perform to its potential
Long 0 Short 6 Throttle position sensor Malfunction
Long 0 Short 9 Manifold Air Pressure sensor Malfunction
Long 1 Short 2 Engine oil temperature sensor Malfunction
Long 1 Short 3 Intake Air temperature sensor Malfunction
Long 1 Short 7 O2/HEGO Sensor Malfunction
Long 4 Short 5 O2 Sensor heater circuit Malfunction
Long 5 Short 4 EXAI Circuit Malfunction
MIL will glow continuous. Engine will NOT start but will crank
Long 6 Short 6 Crankshaft position sensor Malfunction
Long 1 Short 5 Roll over sensor Malfunction
Long 3 Short 3 Fuel Injector Circuit Malfunction
Long 3 Short 7 Ignition Coil Circuit Malfunction
Long 4 Short 1 Fuel pump relay circuit Malfunction
Long 7 short 0 Vehicle/Wheel speed sensor Malfunction( only for Continental GT Model)

LEVEL 3 GENERIC SCAN TOOL METHOD

When the fault is detected, the GST raises a flag to conform readiness Permanent/Confirmed/Pending DTC. If some
DTCs are defined for a sensor or device, a readiness for the sensor or device is judged as formed when one of readiness
for the DTCs is formed.
 NACS II Diagnostic Tool can read the error codes (P – codes in the adjacent table) to easily diagnose the system
causing the malfunction.
 It can also be used to capture engine data for future reference for saving data regarding issues of engine
malfunction before in the process of resolving engine malfunction.

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DIAGNOSTIC TROUBLE CODES DESCRIPTION

Items Parameters Description DTC

Too low input voltage P0120

Throttle position sensor TH
Too High input voltage P0123

Too low input voltage P0107

Manifold Air Pressure sensor PM
Too High input voltage P0105

Too low input voltage P0117

Engine Oil Temperature Sensor TW
Too High input voltage P0115

Too low input voltage P0112

Intake Air Temperature Sensor TA
Too High input voltage P0110

Too low input voltage

Rollover Sensor RO P1630
Too High input voltage

Short circuit to ground or open

O2 Sensor HG
circuit (low or open) P0130

Short circuit to ground or open circuit

Fuel Injector IJ1 P0201
Short circuit to Battery

Short circuit to ground or open circuit

Ignition Coil IG1 P0351
Short circuit to Battery

Short circuit to ground or open circuit

Fuel Pump Relay FLR P0230
Short circuit to Battery

Short circuit to ground or open circuit

O2 sensor Heater HR P0030
(low or open)

Vehicle / Wheel speed sensor VSP The Sensor circuit malfunction P0500

AIR System Switching Valve EXAI Short circuit to ground or open circuit
P0412
“A” Circuit (low or open)

Crankshaft position sensor CRK The Sensor circuit malfunction P0335

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INSTRUCTIONS (DO’S & DON’T’S)
1) DO NOT remove any of the sensor connections / couplers / Battery connections when the Ignition switch is ON OR
the engine is running.

2) DO ensure the battery is in good condition & Fully Charged Battery.

3) DO start the engine only when it is in centre stand or when rider sitting on the vehicle with both the stands retracted.
(Engine will NOT Start OR switch OFF if side stand is extended).

4) DO NOT rev the engine fully – immediately after starting OR just before shutting off the engine.

5) DO NOT remove the fuel hose (high pressure) from the fuel pump to fuel injector, when engine is running OR with
the ignition switch ON. Fuel flows at a very high pressure during these times.

6) DO NOT use a booster or high voltage-charging unit instead of a battery. Use only a good, correctly charged battery
to start OR check the motorcycle.

7) DO NOT use high pressure water jet to clean the ECU / Throttle Body / any of the sensors. Keep them well protected
while washing the vehicle.

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SECTION 06 - NACS II DIAGNOSIS

1. HARDWARE COVERAGE 2. NACS II-ROYAL DIAGNOSTIC TOOL

KIT

NACS II-ROYAL Interface

1. NACS II- 2. Main cable 3. Diagnostic cable
ROYAL Interface (Transfer cable) (6 PIN)

USB Hi-speed cable connector

4.USB Hi-speed 5. Cigarette 6. SD memory

cable lighter cable Card

Reset Button
SD memory card

7. SD card reader 8. Carrying Box 9. Installation CD Diagnostic connector

10. User Manual
(Included on CD)

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3. PRODUCT SPECIFICATION 2. PC
PC  USB Hi-Speed Cable  NACS II-ROYAL
Dimension L:173.78mm x interface  Main Cable  Diagnostic Cable 
W:134.66mm x Motorcycle (IG ON)
H:60.91mm
Weight 660g
Operating Voltage DC 8~18V
Operating Current 300mA
Operating Temperature 00C~+700C
Dust and water resistance IP55 Standard

4. HARDWARE CONNECTION
DIAGRAM
Connect NACS II-ROYAL diagnostic tool kit as below
before performing diagnosis.
1. HAND-HELD
NACS II - ROYAL interface Main cable Diagnostic
cable Motorcycle (IG ON)

5. WARNING
 When NACS II is already connected to the
motorcycle, do NOT plug in AC Adaptor.
 Do not remove SD card when you are using NACS
II.
 The failure caused by the use of unapproved
cables, accessories is out of warranty.
 The warranty will become void if NACS II is
disassembled or altered.
 We recommend you to back up the SD-card data
to avoid data loss due to various reasons.

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 6. TROUBLE SHOOTING s There is a warning message showing on the
screed. Wht’s wrong?
s Why I can not install the software successfully?
A: It means communication breakdown. Please
A: If you are using Windows 7, 8, 10, please check
check whether the cables are connected well.
whether you have turned UAC off before
installation. (Please refer to item No. 8, PC
settings.)
s I have already installed the software. Why the
software can not be opened?
A: Check whether you have run the software as
administrator. Right click ICM logo on the
desktop. Choose ‘Run as admministrator”.

7. PC REQUIREMENTS
Operating system Windows XP, Vista,
Windows 7 /8 / 10
CPU CPU 1.6 GHz or higher
RAM 2GB or larger
Display Resolution 1024*768
Hard Disk Space Free space more than 1GB
(on C driver)
Notes When you use Windows Vista
or Windows 7/8, you need to
close “User Account Control
(UAC)” first. Please refer to
s Why there is a pop-up-window displaying item No. 7. PC Settings.
“cannot find COM port”.?
8. PC SETTINGS
A: Check whether the driver of USB Hi-speed cable
is installed. If USB port is not recognized, please When you use Windows 7 /8 / 10, please finish the
install USB driver. setting below to run out software successfully.
First, you need to disable “User Account Control
(UAC)” before installing our software. The way to
disable UAC is as follows.

8.1
Click ‘Start button’
and select ‘Control
Panel’.

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ROYAL ENFIELD NACS II DIAGNOSIS 9. SOFTWARE INSTALLATION
8.2. 9.1. Start the computer.
Click ‘User Accounts’ 9.2. Insert installation CD to CD-ROM drive and install
following software.
a. Main software: NACSII_ROYAL_V0.03_install.exe
b. Recording data analyzing software: NACSII-
RECORD_ROYAL-V0_01_setup

8.3.
Click ‘Changer User’ Account Control Settings”.

9.3.
Click ‘Finish’ to complete the installation

8.4.
Move the slider to the Never notify position, Click “OK”
to make the change effective.

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ROYAL ENFIELD NACS II DIAGNOSIS
9.4. 9.7.
Click ‘Finish’ to exit installation Click ‘Finish’ to complete the installation

9.5. 10. SOFTWARE REMOVAL

After installing Firmware program, USB high speed 10.1.
driver will start installation. Click ‘Extract’ to install. Click ‘Star Menu’ - ‘All Programs’ - ‘Control Panel’

9.6. 10.2.
Click ‘Next’ to continue Click ‘Uninstall’ a program’

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ROYAL ENFIELD NACS II DIAGNOSIS
10.3.
11. DIAGNOSTIC SOFTWARE FOR
Find ‘NACSII_ROYAL’ and click ‘Change / Remove’. HANDHELD TOOL

11-A.
Diagnosis

11-A1.
Please connect your NACSII-ROYAL diagnostic tool
kit with your motorcycle. NACSII-ROYAL interface-
maincable  Diagnostic cable  Motorcycle
Orange light indicates whether the system is
communicating.

10.4.
When ‘Unistalling NACSII_ROYAL’ window pops up.
please click ‘Next’.

10.5.
11-A2.
Click ‘Finish’ to exit uninstall.
When the IG of the motorcycle is ON, the system
starts to run, entering welcome page ‘ROYAL
ENFIELD’. Press F1 Diagnosis.

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ROYAL ENFIELD NACS II DIAGNOSIS
11-A3. 11-A6.
Select ‘Royal Enfield Press to C exit
534 EFI’. Press OK to ‘Vehicle Info’
continue. page. The page
will return to the
main menu.

11-A4.
NACS II will 11-A7.
automatically detect Using and to
which system the move the cursor.
vehicle is. Select Move the cursor to
‘KEIHIN Engine select ‘Diagnostic
System’ or ‘BOSCH Trouble Code’.
ABS System’. Press OK to see the
Press OK to content.

continue.

11-A5.
11-A8.
Take ‘KEIHIN Engine System’ as an example. After
Diagnostic trouble
pressing OK the system will display ‘Vehicle Model
code page includes
Data’. Press to view the 2nd page of vehicle ‘F1 Current’, ‘F2
information. Press to return to last page. History’ and ‘F4
Erase’. ‘Current’ is
for the DTC occurred
at the time and
‘History’ is for DTC
occurred in the past.
‘Erase’ is for erasing
current DTC and
History DTC. Press OK
to view ‘Current’
DTC.

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ROYAL ENFIELD NACS II DIAGNOSIS
11-A9. 11-A11.
Press F2 to view Erace DTC. It’s the
function to erace
‘History ‘ DTC.
Diagnostic Trouble
Press to view next Code in both
‘Current’ and
page and press
‘History’.
to view last page.
After viewing all the Press F4 to erace.
current DTC. To confirm erasing
Press C to exit. The DTC. Press F1 ‘Yes’.
screen will return to
the previous page.

When showing on the screen, it means the DTC

11-A10. has been erased. Press to go back to the main menu.
Freeze Data. ‘Freeze Data’ is the data recorded when
First DTC occured, and one time only record One DTC
freeze data. It’s for saving the engine dynamic data for
further analysis.

When displays on the screen, press OK to view

freeze data. Press and to view next page and
last page. After viewing all content, press C
to exit. The screen will return to the previous page.

11-A12.
When the screen
returns to the main
menu, move the
cursor to ‘Live Data’
and Press OK to
view the content.

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ROYAL ENFIELD NACS II DIAGNOSIS
11-A13. 11-A16.
Press and to view all the content. Back to the main
menu, move the
cursor to ‘Special
Function’ and
Press OK

‘Special function’ is
customized functions
provided to specific
vehicles.

11-A17.
Select “CO
11-A14. Adjustment”, press
Record data. ‘F2 and to adjust
REC’ is for
the CO value. is for
recording Live data.
When viewing ‘Live increasing fuel
injection value. is
Data’, click to
for decreasing fuel
record current
injection value.
values. Press C to
After finish
stop recording
adjustment, press OK
to save. Press to
exi t. If you want to
go back to the main page, press unti l the page
return to the top of the page.
11-B.
11-A15. 11-B1.
Press F1 to save “F2 Setup” page contains setting Language, viewing
the file. System Information and setting Date / Time.

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ROYAL ENFIELD NACS II DIAGNOSIS
11-B2. 11-C.
Press to view System Information. ABS Functions

11-C1.
Select ‘BOSCH ABS
System’. Press OK
to continue.

11-C2.
Select ‘Special Function’. Then, select ‘Repair Air
Bleed’.
11-B3.

Press to set
Date and Time.

11-B4.
Using and to move the cursor. Press OK to
select the item. Change figure using or
11-C3.
and press OK to confirm the item. At this time, the
pink block will return to white. Press to apply the Read the warning first before start operating air
bleeding.
setting.

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ROYAL ENFIELD NACS II DIAGNOSIS
11-C3. 11-C6.
Read the warning first before start operating air Front Channel
bleeding. Activation

11-C4. 11-C7.
Follow each step on thescreen to finish the Follow the instructions on screen to finish the
procedure. activation.

11-C5. 11-C8.
SILA Lamp Blinking Test Follow the instructions on screen to finish the
Follow the screen guide to finish the test. activation.

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ROYAL ENFIELD NACS II DIAGNOSIS
12. Diagnostic software for PC base 12-3.
When the first time
12-1. you use software,
the software will
Before diagnosis, please connect your NACSII- enter register
ROYAL diagnostic took kit with your motor cycle. process
PC  USB Hi-Speed Cable  NACSII-ROYAL automatically.
interface  Main Cable  Diagnostic Cable  ‘Please make sure
Motorcycle (IG ON) your PC is connected
to the internet.
When the window
displays ‘Product
key’, click ‘NEXT’.
Software will get the
password by itself.

12-4.
Registration is
completed. Click
‘EXIT’.
12-2.
Double click NACSII_ROYAL onthe desktop to open
diagnostic software.

12-5.
This is the page
showing your
connected system.

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ROYAL ENFIELD NACS II DIAGNOSIS

12-6. 12-9.

Click to show There are various

Interface info and green buttons on
Contact info of I.C.M. the right.
button is for
displaying all the
vehicle info.

12-7. 12-10.
Click to switch Click to read the
language. Diagnostic Trouble
After selecting code. Click
language. ‘Current’ toread
Click to confirm current DTC. Click
setting ‘History’ to read
Click to continue. history DTC.

12-11.
12-8.
If you want to
Connecting to
engine system. print trouble

Please wait... code, click

to print DTC
data. It will
take a
moment.

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ROYAL ENFIELD NACS II DIAGNOSIS

12-15.
12-12.
To erase the
The window will pop Diagnostic Trouble
up for selecting
printer. Code, click
Note : if you click the
erase button, all
Diagnostic Trouble
Code in ‘Current’ and
‘History’ will be
erased!

12-13.
If you want to freeze
DTC data, select the
code which has 12-16.
mark. Click to
Click to see
freeze data specification of live
data.

12-14.
This is the page of
freeze data. ‘Freeze
Data’ is the data
racorded when 12-17.
FIRST Diagnostic
Trouble Code Click to see the
occurred, and one live data. You can
time only record one
select ‘All Data’ to
Diagnostic Trouble
Code freeze data, it’s view all live data or
for saving the engine select the item which
dynamic data for used often. Selected
further analysis. items will be listed in
Click to return to
the block of ‘Live
Diagnostic Trouble
Code page. Data Item’.

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ROYAL ENFIELD NACS II DIAGNOSIS
12-17-A. 12-17-D.
Click to erase ALL selected live data. If you want
Click to view selected data values. to erase only one item, please press and hold ‘Shift’
key and select the item that you want to delete.
Then, click button. The selected item will be
erased.

12-17-B.

Click to view wave chart.

12-18.
This button is
for special function.
Functions depend
on ECU type. Take
‘CO adjustment’ as
an example. Select
the item and click
12-17.

Click to view chart of 2 live data items at the

same time. 12-19.
The page will display
‘What to do’ for
next step. Click
to continue.

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ROYAL ENFIELD NACS II DIAGNOSIS

12-20. 13-2.
Adjust CO value Select Record Date
by clicking and File name, then
and click click
to save
adjusted value.

13. RECORD ANALYZING SOFTWARE 13-3.

This software is for reading NACS II handheld Select the items
recorded data. Please take out SD card from NACS II which used often.
handheld tool and insert SD card to PC. Selected items will be
listed in the block of
‘Live Data Item’.
Click to view
wave chart of
selected items.

13-4.
Wave chart starts running until press ‘Stop’ button.
13.1. Drag Yellow line forward and back to view recorded
Open the live data values.
software of
‘NACSII_Record_Royal’.
Select ‘Analyze
Record Data’.

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ROYAL ENFIELD NACS II DIAGNOSIS
13-5. 13-8.
For example, setting Engine speed grater than 3150,
To slow down the playing speed of wave chart,
enter 3150 in the right block. Click to confirm
please drag the slider down.
the setting value.

13-6.
To view different sections of wave chart, please click 13-9.
to select page number. Click the 2nd to go When window pops up ‘Setting OK’, the setting is
completed.
back to last page.

13-7. 13-10.

Select items to set breakdown point for analysis. The setting value will display in the blockunder
After selecting items, click ‘Break’ Click to view wave chart.

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ROYAL ENFIELD NACS II DIAGNOSIS
13-11. 13-14.
Click to quickly find matched point of setting value. Back to Live data selection page, click to view
wave chart of the 2 setting values.

13-12.
Sometimes, setting only one value still can not find the
13-15.
main problem which causes malfunction. In this case,
setting the 2nd value or more values can help user to Click to quickly find the 2 matched conditions.
find satisfied conditions. To set the second value
please select Live data item. Take throttle position as
an example. Enter throttle position grater than 9.8 in
the right block and click to finish setting.

13-16.
13-13. Back to Live data selection page, setting the 3rd
After Setting 2 values of the 2 items, the 2 items will
value as the same way as step 18-8. Click to
be listed in the block of ‘All value match’ Click to
go back to Live data selection page. finish setting.

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ROYAL ENFIELD NACS II DIAGNOSIS
13-17. 13-18.
The 3 setting items will be listed in ‘All value match’
block. To analyze conditions and differences of Click to quick find matched conditions.
values, it’s necessary to select match items. Select
the items and then The selected items will be
listed in ‘Any of value match’ block. Continue to set
match conditions : AND, OR &&, AND : All conditions
of setting items must be satisfied.
OR : One of or any of selected items must be
satisfied. && : Setting items listed in ‘All value match’
and ‘Any of value match’ must be satisfied. If there
isno matched condition, the window will pop up
showing condition can’t match.

After setting condition, click to go back to Live

data selection page.

13-18.
Click to wave chart.

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 SECTION 12 - ELECTRICALS

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SECTION 12.1 - BATTERY

EXPLODED VIEWS
BULLET EFI, BULLET CLASSIC EFI, CONTINENTAL GT

Continental GT

9
1

7
6 4
5

5 8 11

2
3
11

10

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Battery Carrier Assy 1 7 Washer 1

2 Battery Carrier Assy 1 8 Hex. Flanged Bolt M8 X 1.25 X 45 1

3 Cover - Battery Black New 1 9 Cap Battery Carrier - Rubber Rectangle 1

4 Battery - 12V 14AH 1 10 Clip Lock 1

5 Strap Battery 2 11 Phillips Round Head Machined Screw M6X13 2

6 Hex Bolt M8 X 1.25 X 16 1

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.1 Battery -
Dismantling
Bullet Classic EFI/
Bullet EFI
 The battery is located on
the left side of the
motorcycle.

 Ensure the motorcycle is

parked on its center
stand, in a well ventilated
area.

 Ensure the ignition

switch and engine stop
switch are in OFF
position.

 Unlock and remove the

battery cover.

 Remove the two straps

holding the battery to NOTE :
the battery carrier.
Disconnect -VE terminal
FIRST and the +VE terminal
NEXT.

 Pull the battery out

slightly from the battery
carrier.

 Remove the battery

from the carrier.

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No. Instructions
12.1 Battery -
Dismantling
Continental GT
 The battery is located on
the left side of the (-) (+)
TERMINAL TERMINAL
motorcycle.

 Ensure the motorcycle is

parked on its center
stand, in a well ventilated
area.

 Ensure the ignition

switch and engine stop
switch are in OFF
position.

 Unlock and remove the

battery cover.

 Remove the battery

carrier bracket by
loosening the two
screws.

 Pull the battery out

NOTE :
slightly from the battery
carrier. Disconnect -VE terminal
FIRST and the +VE terminal
 Remove the battery NEXT.
from the carrier.

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INSPECTION
NOTE :
Always disconnect -ve cable FIRST and then +ve cable next from the battery terminals.

 Clean the terminals using a soft wire brush to remove any oxidations.
 Check the electrolyte level to see if it is between MAX and MIN lines.
 Check and ensure the specific gravity of the electrolyte and the terminal voltage are as per the recommendations
of the battery manufacturer.
 Inspect the battery screws, clamps and cables for oxidation, breakage, loose connections and corrosion.
 Clean the battery well using a soft and wet cloth.
 Inspect the battery carefully for any deformation of its housing. If found deformed, replace the battery
immediately.

CAUTION:
If necessary top up ONLY with pure and clean distilled water till the level is between the MAX and MIN lines. DO NOT
OVERFILL as it will overflow through the vent hole of the battery and cause irreparable damage to the motorcycle
parts.

WARNING
Motorcycle batteries contain lead and lead components, acids and chemicals known to cause cancer, birth defects or
other reproductive harm. Exercise extreme caution while handling a battery. Wash hands thoroughly whenever a
Battery is handled.
 Do not smoke or allow open flame or sparks in the vicinity.
 Store the battery carefully and ensure the terminals dok not come into contact with any metal surface which will
result in a short circuit.
 Do not short the battery terminals as it might result in an explosion of the battery.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.1 Battery -
Assembling
Bullet Classic EFI/
Bullet EFI
 Locate the battery in the
carrier with the terminals
facing inside.
 Connect the +VE
terminal wire first.
 Connect the -VE terminal
wire next.
 Ensure the terminals are
firmly connected.
 Apply a coat of petroleum
jelly or battery terminal
protector to prevent
oxidation of the
terminals.

 Ensure the protective

covers are properly
located over the
terminals to prevent any
metal coming in contact
with the terminals and
causing a short circuit

 Position the battery

correctly and fully inside
the carrier and strap the
battery securely using
the two rubber straps.
 Locate the battery cover
over the battery and
lock it in place.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.1 Battery -
Assembling
Continental GT
 Locate the battery in the
carrier with the terminals (-) (+)
TERMINAL TERMINAL
facing inside.

 Connect the +VE

terminal wire first

 Connect the -VE terminal

wire next.

 Ensure the terminals are

firmly connected.

 Apply a coat of petroleum

jelly or battery terminal
protector to prevent
oxidation of the
terminals.

 Ensure the protective

covers are properly
located over the
terminals to prevent any
metal coming in contact
with the terminals and
causing a short circuit.

 Position the battery

correctly and fully inside
the carrier.

 Locate the battery cover

over the battery and
lock it in place.

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SECTION 12.2 - HEAD LAMP, TAIL LAMP,
TRAFFICATOR, CLUSTER & ITS BULBS

EXPLODED VIEWS
HEAD LAMP & PILOT LAMP

15 12
6 14 13

4 1 10
3 2
5
11
8
6 7 16
17
18
13
7 9 22
22 19

21
20

20
21

Continental GT

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Pilot Lamp With Bulb 2 12 Rim Assy. 1

2 Bulb 2 13 Housing Assy. 1
3 Screw Pilot Lamp Rim Fixing 2 14 Bulb Holding Spring 1
4 Bulb 12V - 2W Ba 7S Cap 2 15 Bulb 12V (T4W) 1
5 Head Lamp Assy. with Halogen Bulb LHT 1 16 Housing Locating Bracket 1
6 Head lamp Bulb 12V, 60 / 55W Halogen 1 17 Pan Head Screw 1
7 Bulb 12V - 4W BA 7S Cap 1 18 Head Lamp Holder RH 1
8 Screw Rim Fixing Top with Clamp 1 19 Head Lamp Holder LH 1
9 Pan Head Screw M5 X 0.8 X 12 2 20 Washer 2
10 Head Lamp Assy. with Bulb 1 21 Flanged Hex. Bolt M8 X 30 2
11 Lens and Reflector Assy 1 22 Hex. Socket Head Cap Screw M6 X 20 2

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Pilot Lamp
Bullet EFI/Bullet
Classic EFI
Dismantling
 Loosen 2 pilot lamp rim
fixing screw on LH & RH
side.
 Gently remove the bulb
from its holder

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Pilot Lamp
Bullet EFI/Bullet
Classic EFI
Assembling
 Locate the Pilot lamp
bulb in the holder
 Install 2 pilot lamp rim
fixing screw on LH & RH
side.

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No. Instructions
12.2 Head Lamp
Bullet Classic EFI/
Bullet EFI
Dismantling
 Loosen rim fixing top
with clamp screw
mounted on head lamp
rim assembly
 Loosen 2 pan head
screws on LH & RH side
mounted on head lamp
housing assembly.

 Gently Remove head-

lamp assembly. Pan Head Screw M5
Philips Screw Driver
 Remove the rubber
grommet from the bulb

 Gently Press the clip by

thumb to release the free CAUTION:
end from bulb holder. Never touch the bulb with
your fingers, Finger prints
will etch the glass and
 Gently pull out the bulb. decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Head Lamp
Continental GT
Dismantling
 Loosen screw fixing top
with clamp pan head Philips Screw Driver
lamp mounting assembly.

 Loosen 2 hex bolt along

with washer on LH & RH Flanged Hex Bolt M8
side mounted on the
Socket spanner 13 mm
front end of the
headlamp Holder.
Hex Socket head cap
 Remove 2 hex socket screws M6
head cap screws from Philips Screw Driver
the inner side of head
lamp holder on LH & RH
side.

 Gently remove the

headlamp assy.

 Thumb push and

remove the bulb holding CAUTION:
clamp. Never touch the bulb with
 Gently remove the bulb. your fingers, Finger prints
will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Head Lamp Bulb
Bullet Classic EFI /
Bullet EFI
Assembling
 Locate the bulb into
reflector unit of the
headlamp.

 Gently press the bulb

holding clip and lock the
free end in its slot.

 Locate the rubber

grommet.

 Connect the electrical

connections carefully &
assemble the headlamp.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Head Lamp
Bullet Classic EFI/
Bullet EFI
Assembling
 Locate head lamp assembly. Pan Head Screw M5
 Install 2 pan head screws Philips Screw Driver
on LH & RH side mounted
on head lamp housing
assembly.
 Install Screw on rim
fixing top with clamp
mounted on head lamp
rim assembly.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Head Lamp Bulb
Continental GT
Assembling
 Install the bulb holding
clamp.
 Connect the Electrical
connections.

 Locate the headlamp Hex socket head cap

assembly. screw M6
 Install 2 hex socket head Philips Screw Driver
cap screws on the inner
side of head lamp holder
on LH & RH side.
Flanged Hex Bolt M8
 Install 2 hex bolt along
with washer on LH & RH Socket spanner 13 mm
side and mount on the
front end of the
headlamp Holder. Philips Screw Driver
 Install screw fixing top
with clamp on head lamp
mounting assembly.

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EXPLODED VIEWS
TAIL LAMP
1
Bullet & Classic Models
6 6 2

6 6

4 3

6
6

Continental GT 2

5
8

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Tail Lamp 1 5 Bulb 12V 21/5W - Tail Lamp 1

2 Lens & Base Sealed, Classic 1 6 Plain Washer M6 6

Lens Complete - Tail Lamp 1 7 Pan Head Tapping Screw - Tail Lamp 2

3 Cross Recessed Pan Head Screw M6 X 14 3 8 Tapping Screw - Tail Lamp 2

4 Bulb - Tail Lamp 12V, 21/5 W 1

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Tail Lamp
Bullet Classic EFI/
Bullet EFI
Dismantling
 Loosen 2 Nyloc nuts
mounted on LH & RH side Hex Nyloc Nut M6
on the complete tail lamp Double end spanner 8mm
bracket.

 Disconnect the tail lamp

coupler.

 Gently pull out Tail Lamp

assembly along with tail
lamp bracket

 Gently rotate the bulb

holder in anticlockwise
to remove the bulb from
its holder assembly.

 Gently pull out the bulb.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Tail Lamp
Continental GT
Dismantling
 Refer Section 5.4 for seat
removal. Pan head tapping screw
 Loosen 2 pan head Philips Screw Driver
tapping screws mounted
on tail lamp LH & RH sides
 Remove 2 tapping screws
mounted on inner side
of tail lamp on both LH &
RH sides

CAUTION:
Never touch the bulb with
your fingers, Finger prints
will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

 Gently remove the Tail

lamp assembly Tapping screws
Philips Screw Driver

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Tail Lamp
Bullet Classic EFI/
Bullet EFI
Assembling

 Locate the bulb in the tail

lamp Hex Nyloc Nut M6

 Locate Tail Lamp Double end spanner 8mm

assembly on the tail lamp
bracket
 Connect the tail lamp
coupler
 Install 2 Nyloc nuts
mounted on LH & RH side
on the complete tail lamp
bracket.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Tail Lamp
Continental GT
Assembling
 Gently hold the bulb,
push inside & rotate CAUTION:
clockwise to locate the Never touch the bulb with
bulb on the holder. your fingers, Finger prints
will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

 Locate Tail lamp

assembly.
 Install 2 tapping screws
and mount on inner side
of tail lamp on both LH &
RH sides

 Install 2 pan head

tapping screws and Pan head tapping screw
mount on tail lamp LH & Philips Screw Driver
RH sides.
 Refer Section 5.4 for seat
assembly Tapping screws
Philips Screw Driver

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EXPLODED VIEWS
TRAFFICATOR LIGHTS

Bullet & Classic Models Continental GT

6
2
1 5

8
4 7
3

11

10
12

S. NO. DESCRIPTION QTY. S. NO. DESCRIPTION QTY.

1 Trafficator Assy. - RH - Front 1 8 Trafficator Assy. - With Bulb - Rear RH 1

2 Trafficator Assy. - LH - Front 1 9 Bulb 12V 10W 4

3 Trafficator Assy. - RH - Rear 1 10 Bracket LH, Front - Black 1

4 Trafficator Assy. - LH - Rear 1 11 Bracket RH, Front - Black 1

5 Trafficator Assy. - With Bulb - Front RH 1 12 Nut, Nylock M8 X 9.5 2

6 Trafficator Assy. - With Bulb - Front LH 1

7 Trafficator Assy. - With Bulb - Rear LH 1

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Trafficator
Bullet Classic EFI/
Bullet EFI
Dismantling
 Loosen 2 Nyloc nuts
mounted on RH & LH Nyloc Nut M8
Bracket in the trafficator Double End Spanner
 Gently remove the 13 mm
Trafficator assembly on
LH & RH side

 Press bulb gently & Turn

Never touch the bulb with
anticlockwise to take out
your fingers, Finger prints
the bulb. will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Trafficator
Continental GT
Dismantling

 Loosen 2 hex screws on

Hex socket head cap
LH & RH side mounted
screw M6
on the rear end of the
headlamp holder. Socket spanner 10mm
 Gently remove the
Trafficator assembly on
LH & Rh side from the
headlamp holder

 Pull out the Indicator

Never touch the bulb with
housing.
your fingers, Finger prints
will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Trafficator
Bullet Classic EFI/
Bullet EFI
Assembling
 Press bulb gently & Turn
clockwise direction to
locate the bulb in the
holder.

 Locate the Trafficator

assembly on LH & RH Nyloc Nut M8
side. Double End Spanner
 Install 2 Nyloc nuts on RH 13 mm
& LH side of the
brackets.

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Trafficator
Continental GT
Assembling

 Locate the bulb Never touch the bulb with

your fingers, Finger prints
will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

 Locate Trafficator
assembly into the Hex socket head cap
headlamp holder on LH screw M6
& RH side. Socket spanner 10mm
 Tighten 2 hex screws on
LH & RH side and mount
on the rear end of the
headlamp holder.

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CLUSTER / CONSOLE

S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Console
Bullet Classic EFI/
Bullet EFI
Dismantling
 Refer Section 11.2 for
Headlamp dismantling
 Disconnect the coupler
mounted on
speedometer.
 Loosen the nut
mounted on bottom
side of speedometer in
clockwise direction.
 Gently push the
speedometer upwards
from bottom end of
speedometer unit such
that it will come out from
the speedometer slot.

12.2 Instrument Cluster

Continental GT
Dismantling
 Disconnect the coupler
 Loosen 4 hex screws on
both LH & RH side
mounted on the
Instrument cluster
bracket assembly.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Console
Bullet Classic EFI/
Bullet EFI
Assembling
 Gently push the
s p e e d o m e t e r
downwards from top
end of speedometer
unit such that it will get
seated in the
speedometer slot.
 Install the nut on bottom
side of speedometer in
Anti-clockwise direction
 Connect the coupler
mounted on
speedometer
 Refer Section 11.2 for
Headlamp Assembling.

12.2 Instrument Cluster

Continental GT
Assembling
 Install 4 hex screws on
both LH & RH side on
the Instrument cluster
bracket assembly.

 Connect the Couplers.

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CONSOLE BULBS REPLACEMENT

S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Console Bulb
Bullet Classic EFI /
Bullet EFI
Dismantling
 Disconnect the couplers
 Gently pull out the bulb
(Speedo meter/Neutral/
High beam& Low beam/
Turn Signal Bulbs) from
its holder.

12.2 Cluster Bulb

Continental GT
Dismantling
 Disconnect the couplers.
Never touch the bulb with
 Gently pull out the out your fingers, Finger prints
the bulb. will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.2 Console Bulb
Bullet Classic EFI /
Bullet EFI
Dismantling
 Gently fix the bulb
Never touch the bulb with
(Speedo meter/Neutral/
your fingers, Finger prints
High beam& Low beam/
will etch the glass and
Turn Signal Bulbs) on the decrease bulb life. Always
holder. hold the bulb with paper or
 Connect the couplers. clean dry cloth during
handling.

12.2 Cluster Bulb

Continental GT
Dismantling
 Gently locate bulb on the
Never touch the bulb with
holder.
your fingers, Finger prints
 Connect the couplers will etch the glass and
decrease bulb life. Always
hold the bulb with paper or
clean dry cloth during
handling.

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SECTION 12.3 - ELECTRICAL COMPONENTS

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STARTER MOTOR

WIRING LAYOUT

SCHEMATIC DIAGRAM OF E-START

MECHANISM - UCE MODELS

Crank Shaft
Jack Shaft

Sprag Clutch Gear

Sprag Clutch
Bearing Jack Gear
Engien Sprocket Double
Gear Self Motor
Big / Small Pinion

TECHNICAL SPECIFICATIONS
System / Battery 12V DC / 12V 14 Ah

Starter Motor 0.9 KW

Solenoid Switch Magnetic Relay type

INSPECTION
Ensure earth terminal is located on the outside hex flange bolt of the starter motor before tightening both bolts.

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RELAY STARTER
WIRING LAYOUT

Schematic Diagram - Relay

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INSPECTION
1. COIL RESISTANCE CHECK
a. Set the Multimeter in Resistance check mode.
b. Keep the positive (Red) probe of the Multimeter on coil positive and Negative probe(Black) of the Multimeter on
coil negative.(Refer the below table for polarity identification).
c. Resistance Spec – 3.24 to 3.96 
d. If resistance deviates from the specification or if coil is open/short , Relay starter to be replaced.

Sl.No. Euro IV Coil Polarity & Wire Color

1. Classic 500 Coil +ve = Blue
Model Coil -ve = White

2. GT Coil +ve = Brown / Green

Model Coil -ve = Brown / Blue

1. TO CHECK -CONTACT CLOSURE AFTER ENERGISING:

1. Give a supply voltage of 12V across the relay coil ( 2 pole female terminal). Battery positive on coil positive and
Battery negative on coil negative.

2. After energizing the coil, check the continuity between Battery +ve terminal and Starter +ve terminal (Ring
terminal) using Multimeter. If the Multimeter indicates 0Ù with a beep sound, the contacts have got closed. If the
Multimeter indicates as open (OL) ,contacts have not closed and hence the Relay starter has to be replaced.

Starter motor +ve eyelet terminal

Energised the relay

Battery +ve terminal using battery

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RR UNIT

INSPECTION
STEP 1 :
Check the condition of the six diodes used in the RR Unit.
Take the Multimeter and change the mode to diode check mode. Diode mode would be available in continuity mode.

NOTE :
Before checking the diode, internal capacitor of RR unit to be discharged. Else, the diode drop will not be correct. So
short the positive and negative terminal of RR Unit DC output(black and red wires) to discharge the capacitor.

STEP 2 :
To check the condition of 3 positive diodes of RR unit, keep the positive probe (Red) of the multimeter in any one of
the 3phase terminals (yellow wire inserted in black/red connector) and the negative probe (Black) of multimeter on
the positive terminal of DC output (red wire inserted in two pole connector) and check for the condition of diode as
shown in the below image.
If the diode is good, then the multimeter will show a voltage drop of 0.4~0.7V.
If diode has failed, multimeter will show either open or short with beep sound, then Replace the RR unit.

3 Phase AC Terminals

DC Output Positive Terminals

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STEP 3 :
The positive probe of the multimeter shall be kept on all the 3 phase terminals one by one and the
condition of the 3 diodes to be checked as mentioned in Step 2.

STEP 4 :
To check the condition of other 3 negative diodes, positive probe (Red colour) of the multimeter shall be kept on the
negative terminal of DC output (black wire with eyelet/single pole connector) and negative probe (Black colour) of
the multimeter shall be kept on anyone of the 3 phase terminals (yellow wire).
If the diode is good, then the multimeter will show a voltage drop of 0.4~0.7V.
If diode has failed, multimeter will show either open or short with beep sound, then Replace the RR unit.

STEP 5 :
All the three diodes to be checked by keeping the multimeter negative probe on all the 3 phase terminals one by one.
If the RR Unit is not working, replace with good working RR Unit.

3 Phase AC Terminals

DC Output Terminals

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SUPRESSOR CAP

INSPECTION
STEP 1 :
1. Set the Multimeter in Resistance check mode.
2. Keep the positive(Red) and negative (Black)probes of the multimeter on two ends of the suppressor cap.
3. Resistance shall be 3.75 to 6.25 Kilo Ohms

4. If resistance deviates from the specification or open , Suppressor cap to be replaced.

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FLYWHEEL MAGNETO

INSPECTION
A) PHASE TO PHASE RESISTANCE CHECK
1. Phase to phase resistance of the magneto shall be checked by setting multimeter in resistance mode.
2. Phase to Phase resistance – 0.59 to 0.72 
3. If the resistance deviates from the spec, then cover shall be opened and checked if stator coil has burnt. If stator
coil is burnt then replace the magneto.
If multimeter shows open during resistance check, the coil has got cut or short with the core and magneto has to be
replaced.

B) INSULATION TEST
1. For checking the insulation strength, keep the multimeter in continuity mode and check continuity between
any 3 phase terminals and engine body. If there is a body short(insulation failure), multimeter will indicate 0ohms
(or resistance value ~ 50 ohms) with a beep sound.
If insulation failure is observed, failed magneto to be replaced with new magneto.
 2. During visual inspection, if stator coil has burnt, magneto shall be replaced with new magneto.

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HORN

INSPECTION
STEP 1 :
1. Set the Multimeter in Continuity check mode.
2. Check for presence of continuity by keeping the horn coupler.

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FUSES

FUSE - USAGE LIST

For easy reference the individual fuse ratings and its function is mentioned inside the lid of the fuse box.
 Whenever a spare fuse is used, please ensure it is replenished at the earliest opportunity
 Always get the circuit checked to ascertain the cause of a fuse blowout and rectify to prevent fuses blowing
frequently.

BLADE FUSE USAGE LIST – BULLET CLASSIC EFI /BULLET EFI

Fuse No. Colour Remarks

1 White Charging Fuse (25A)
2 White Main Fuse (25A)
3 Blue Ignition - EFI Fuse (15A)
4 Red Signalling / Horn Fuse (10A)
5 Brown Spare Fuse (5A)
6 Blue Lighting Fuse (15A)
7 White ABS Main Fuse 1 (25A)
8 Red ABS Main Fuse 2 (10A)
9 Brown ABS ECU (5A)
10 White Spare Fuse (25A)
11 Blue Spare Fuse (15A)
12 Red Spare Fuse (10A)

BLADE FUSE USAGE LIST – CONTINENTAL GT

Fuse No. Colour Remarks
1 White Charging Fuse (25A)
2 White Main Fuse (25A)
3 Blue Ignition - EFI Fuse (15A)
9
8 4 Red Signalling / Horn Fuse (10A)
10
11 7 5 Red Horn Fuse (10A)
6
12 5 6 Blue Lighting Fuse (15A)
4
13 3 7 White ABS Main Fuse 1 (25A)
2 8 Red ABS Main Fuse 2 (10A)
1
9 Brown ABS ECU (5A)
10 White Spare Fuse (25A)
11 Blue Spare Fuse (15A)
12 Red Spare Fuse (10A)
13 Brown Spare Fuse (5A)

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COUPLERS

S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.3 Electrical
connections
A. Magneto coupler
 Disconnect yellow wired
Black coupler from LH
side.

12.3 B. Pulsar Coil

coupler
 Disconnect Green wired
Black coupler from LH
side.

12.3 C. Pulsar Coil

coupler
 Disconnect Green wired
Black coupler from LH
side.

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.3 Electrical
connections
D. Relay Starter
Coupler
 Disconnect Relay starter
(WHITE) and Battery
Coupler (RED) from LH
Side.

12.3 E. Ignition Coil

Coupler
 Disconnect white
coupler from LH side.

·
12.3 F. ECU Power Relay
& Side stand Switch
indication relay
 Disconnect ECU Power
relay and side stand
switch relay.

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SWITCHES

S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.3 Switch Module RH
Bullet Classic EFI /
Bullet EFI /
Continental GT
 Loosen the 2 Pan head
screws mounted on Pan head hex Screw M5
bottom side of Switch Philips Screw Driver
Module RH

 Gently open the RH

switch module top and
bottom portion to
access the RH Switch.

 Remove 2 pan head

screws mounted on RH
switch on LH & RH side.

 Gently remove the

switch module RH

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.3 Switch Module RH
Bullet Classic EFI /
Bullet EFI /
Continental GT
 Locate the RH switch
module

 Install 2 pan head screws

on RH switch on LH & RH
side.

 Close the RH Switch

module cover top and Pan head hex Screw M5
bottom portion Philips Screw Driver

 Install the Pan head

screw mounted on
bottom side of Switch
Module RH

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 S. Aggregate to Dismantle /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.3 Switch Module LH
Bullet Classic EFI /
Bullet EFI /
Continental GT

 Loosen the 2 Pan head Pan head hex Screw M5

screws mounted on
bottom side of Switch Philips Screw Driver
Module LH

 Gently open the LH

switch module top and
bottom portion to
access the LH Switch

 Gently remove the

switch module LH

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 S. Aggregate to Assemble /
Fastener, Size, Tool Usage, Precautions, Photos
No. Instructions
12.3 Switch Module LH
Bullet Classic EFI /
Bullet EFI /
Continental GT

 Locate the LH switch

module

 Close the LH Switch

module cover top and Pan head hex Screw M5
bottom portion Philips Screw Driver

 Install 2 Pan head screwS

mounted on bottom
side of Switch Module
LH

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SECTION 12.4 - WIRING DIAGRAM

BULLET EFI / BULLET CLASSIC EFI - WIRING HARNESS CIRCUIT

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BULLET EFI / BULLET CLASSIC EFI - STARTING, CHARGING & IGNITION (EFI) SYSTEM

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BULLET EFI / BULLET CLASSIC EFI - LIGHTING & SIGNALING SYSTEM

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BULLET EFI / BULLET CLASSIC EFI - WIRING HARNESS-ABS SYSTEM

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CONTINENTAL GT - WIRING HARNESS CIRCUIT

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CONTINENTAL GT - STARTING, CHARGING & IGNITION (EFI) SYSTEM

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CONTINENTAL GT - LIGHTING & SIGNALING SYSTEM

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CONTINENTAL GT - WIRING HARNESS-ABS SYSTEM

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SECTION 13 - TROUBLE SHOOTING

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SECTION 13.1 - VEHICLE TROUBLE SHOOTING

WARNING
The trouble shooting section of this Owner’s Manual is intended solely as a guide for diagnosing problems. Carefully
read the appropriate sections of this manual before performing any work. Repair and maintenance operations not
listed in this Owner’s Manual should be performed by your Royal Enfield Authorized Dealer only. Improper repair /
maintenance could result in the motorcycle not functioning properly or injury seriously.

WARNING
The trouble shooting section of this Owner’s Manual is intended solely as a guide for diagnosing problems. Carefully
read the appropriate sections of this manual before performing any work. Repair and maintenance operations not
listed in this Owner’s Manual should be performed by your Royal Enfield Authorized Dealer only. Improper repair /
maintenance could result in the motorcycle not functioning properly or injury seriously.

CAUSES REMEDIES
I. ENGINE FAILS TO START
1) Stop switch in ‘OFF’ Position Push stop switch to ‘ON’ position.
2) Side stand not retrieved Retrieve side stand.
3) Vent hole clogged in fuel tank cap Clean vent hole.
4) Spark plug cap / lead not connected Fix cap / lead firmly
5) Spark plug electrode dirty / fouled Clean spark plug
6) Spark plug insulation cracked Replace spark plug
7) Clutch slipping *Adjust clutch cable free play
8) Main or EFI Fuse failed................... Replace with new fuse
II. ENGINE MISFIRING
1) Loose spark plug cap Fix cap / lead firmly
2) Spark plug fouled Clean spark plug or non specified heat range plug.
3) Any sensor loose connections * Check MAP or EOT or TPS sensor wiring / coupler loose
connections
4) Water in petrol tank * Clean petrol tank. Fill tank with fresh petrol.
III. POOR PICKUP
1) Brake pedal adjusted too tight *Re-adjust properly
2) Choked air filter Clean / Replace air filter
3) Rear chain adjusted too tight *Re-adjust properly
4) Under inflated tyres *Inflate to correct pressure
5) Accelerator cable free play excessive Adjust cable free play
6) Clutch Slipping *Adjust clutch cable free play
7) Faulty fuel supply *Remove fuel pump & clean.
Fuel pump, filter / injector blocked

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 CAUSES REMEDIES
IV. WHITE/BLUE SMOKE
1) Oil level in sump above the Top line. *Check and drain excess oil
in the oil level window
V. ENGINE OVERHEATING
1) Low engine oil level Check and top-up if necessary
2) Clutch slipping * Check and correct
3) Cylinder fins not clean Clean the cylinder fins at regular intervals
VI. EXCESSIVE FUEL CONSUMPTION
1) Under inflated tyres Inflate to correct pressure
2) Choked air filter Clean / Replace
3) Fuel leakage *Check and rectify, tank float unit, drain pipe, breather
pipe, fuel line / pump.
VII. BRAKES POOR
1) Brake pad worn / Uneven wear *Replace Brake pads
2) Oil/grease on disc. *Clean and refit
3) spongy brake *fill brake fluid & remove air from the system.
VIII. MOTORCYCLE WOBBLES
1) Under inflated tyres Inflate to correct pressure
2) Loose / Broken spokes * Tighten / Replace spokes
3) Wheels misaligned * Ensure proper alignment
4) Wheel rim runout * Rectify
5) Tyres not fitted correctly * Refit tyres correctly
IX. ELECTRICALS
Bulbs do not glow
1) Bulb fused * Replace bulb
2) Fuse blown * Check and Replace fuse.
3) Loose / improper connection * Check and correct
Horn not working
1) Fuse blown Check and correct
2) Loose connections Check and correct
Trafficators not working
1) Loose / improper connections Check and correct
2) Bulb fused Replace

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 CAUSES REMEDIES
Brake light remains on
1) Switch not adjusted properly * Adjust connecting links properly
2) Switch sticky * Replace switch
Horn not working
1) Fuse blown Check and correct
2) Loose connections Check and correct
Trafficators not working
1) Loose / improper connections Check and correct
2) Bulb fused Replace
Brake light remains on
(1) Switch not adjusted properly * Adjust connecting links properly
(2) Switch sticky * Replace switch
X. ELECTRONIC FUEL INJECTION (EFI)
Malfunctioning Indicator Lamp (MIL) glowing continuously
(1) Sensor Coupler Loose Connection * Check for any EFI sensor coupler loose connection
and correct them
(2) Any EFI Sensor Failure * Check & replace the same
XII. ABS (ANTI LOCK BRAKING SYSTEM)
1) ABS lamp continuously ON. Take the vehicle to service center for diagnosis

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1. ENGINE CRANKS BUT DOES NOT START
Symptom Probable Cause Remedy
Battery voltage low Recharge/ replace battery
Spark plug cap / high tension wire Check & correct
loose / shorted / defective
Spark plug incorrect Replace with correct spark plug
A. Ignition spark weak
Spark plug sooty / wet Check &clean spark plug
Spark plug gap incorrect Correct spark plug gap
Spark plug insulator cracked Replace spark plug
No spark from Ignition coil Check & Replace Ignition coil
Pulsar coil defective Check & Replace
Battery dead Recharge/ replace battery
Spark plug cap / high tension wire Check & correct
shorted / defective / disconnected
B. No Ignition spark
Spark plug insulator cracked Replace spark plug
No spark from Ignition coil Check & Replace Ignition coil
Pulsar coil defective Check & Replace
No Fuel in fuel tank Fill fuel tank.
Stale / adulterated fuel Clean fuel tank
Fill with fresh fuel
Fuel Tap in Closed Position Turn fuel knob to On/Reserve
C. Fuel related Air vent blocked in fuel cap Clean air vent/s
Fuel filter clogged Clean fuel filter
Fuel line pinched Check & correct fuel line
Ambient temperature too low for Use Choke for starting in cold
engine to start conditions
Choke Left ON Shut OFF choke
Spark plug loose Tighten spark plug to torque
Tappets adjusted too tight Check & adjust tappets to specn
Cylinder head gasket blown Check & replace
Cylinder head nuts loose Check & tighten to torque
D. Compression related Cylinder head warped Check & replace
Valve stem bent, seating area Check & replace
burnt, excess carbon deposit on
seating area, Valve springs broken
Piston rings sticky/ worn-out Check & replace
Cylinder barrel / Piston excess Check & replace
clearance

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2. ENGINE DOES NOT CRANK
Symptom Probable Cause Remedy
Ignition key not in ON position Switch ON ignition key
Engine Kill switch in OFF position Switch ON engine Kill switch
Gears not in neutral (neutral lamp Depress clutch / shift to correct
not glowing) neutral & start
Battery voltage low Check battery. Recharge
replace battery
Starter circuit Fuse blown Check all fuses & replace blown
A. Starter motor does not rotate fuse
Starter motor connections loose Check & tighten connections
Starter relay connections loose Check & tighten connections
Ignition Switch defective Check & replace Ignition switch
Starter button defective Check & replace RH switch.
Starter relay failed Check & replace starter relay
Starter motor failed Check & replace starter motor
Major short in Wiring harness Check & correct wiring harness
Motor rotates slowly due to low Check & correct battery /
B. Starter motor rotates battery / worn out starter motor starter motor
BUT engine does brush
not crank Magneto rotor woodruff key broken Check & replace woodruff key
Starter clutch assembly slipping Check & replace starter clutch
assy
Inlet/ Exhaust rocker arm seized in Investigate cause of seizure,
rocker shaft check & correct as required
Cam shaft seized in cylinder Investigate cause of seizure,
head/cover check & correct as required
Cam chain jammed in sprocket Investigate cause of seizure,
gears check & correct as required
C. Engine does not crank and Piston Seized in cylinder barrel Investigate cause of seizure,
sounds locked. check & correct as required
Piston Pin seized in connecting Investigate cause of seizure,
rod small end check & correct as required
Big end bearing seized in Crank Investigate cause of seizure,
pin / connecting rod big end check & correct as required
Crankshaft bearings in LH/RH Investigate cause of seizure,
crankcases seized check & correct as required

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3. IDLING ERRATIC / ENGINE MISFIRING AT LOW RPM
Attribute Probable Cause Remedy
Battery voltage low Recharge/ replace battery
Suppressor cap/ H T lead loose Check & correct as required
Suppressor cap/ H T lead defective Check & correct as required
A. Ignition related
Spark plug fouled / wet Replace / clean spark plug
Electrode gap too less/excessive Check and correct electrode gap
Spark plug wrong specifications Replace with correct spark plug
Ignition coil defective Check & replace
Pulsar coil / Magneto defective Check & replace
Adulterated / Bad fuel Clean fuel tank.
Fill with fresh fuel
Air vent holes in Fuel tank cap Check & clean air vents
partially blocked
B. Fuel / Induction related
Fuel flow partially blocked Check & clean fuel tap / filter
Air filter dirty / clogged Check & clean / replace
Pulse air valve pipe connections Check & correct
loose / cracked
Spark plug loose Check & tighten to torque
Inlet / Exhaust tappets adjusted Check & correct
wrongly
Cylinder head gasket blown Check & correct
Cylinder head studs loose Check & tighten to torque
Cylinder head seating area warped Check & replace
C. Compression related
Cam shaft sticky rotation /seized Check & correct
in cylinder head
Valve spring broken or weak Check & replace
Valve not seating properly (stem Check & replace
bent. Heavy carbon deposit on
seating surface)
Piston rings worn out/ broken / Check & replace
stuck in ring groove
Cylinder / piston worn Check & replace

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4. PICKUP POOR / SLUGGISH
Attribute Probable Cause Remedy
Suppressor cap/ H T lead defective Check & correct as required

A. Ignition related Spark plug fouled / wet Replace / clean spark plug
Electrode gap too less/excessive Check and correct electrode gap
Spark plug wrong specifications Replace with correct spark plug
Ignition coil defective Check & replace
Pulsar coil / Magneto defective Check & replace
Adulterated / Bad fuel Clean fuel tank.
Fill with fresh fuel
B. Fuel / Induction related Fuel flow partially blocked Check & clean fuel tap / filter
Air filter dirty / clogged Check & clean / replace
Pulse air valve pipe connections Check & correct
loose / cracked
Spark plug loose Check & tighten to torque
Inlet / Exhaust tappets adjusted wrongly Check & correct
Cylinder head gasket blown Check & correct
Cylinder head studs loose Check & tighten to torque
Cylinder head seating area warped Check & replace
C. Compression related Cam shaft sticky rotation /seized Check & correct
in cylinder head
Valve spring broken or weak Check & replace
Valve not seating properly (stem Check & replace
bent. Heavy carbon deposit on
seating surface)
Piston rings worn out/ broken / Check & replace
stuck in ring groove
Cylinder / piston worn Check & replace
Rear chain tension too slack / tight Check & correct
No free play in clutch / clutch release sticky Check & correct
D. Transmission related
Engine oil quantity too high Check & correct
Engine oil wrong grade/ high viscosity Check & correct
Clutch plates worn out / warped / Check & correct
sticky release / burnt
Front / rear brakes jamming Check & correct
E. Others
Front / rear wheel bearing jammed Check & correct

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5. ENGINE MISFIRING AT HIGH SPEEDS/ HIGH RPM.
Attribute Probable Cause Remedy
Spark plug electrode gap too less/ Check and correct electrode gap
excessive

Spark plug wrong specifications Replace with correct spark plug

A. Ignition related Spark plug insulator cracked Check & replace

Suppressor cap/ H T lead loose Check & correct as required

Suppressor cap/ H T lead defective Check & correct as required

Ignition coil defective Check & Replace

Pulsar coil / Magneto defective Check & replace

Adulterated / stale fuel / water Check, Clean fuel tank.

content in fuel Fill with fresh fuel

Fuel flow partially blocked Check & clean fuel tap / filter

B. Fuel / Induction related Inlet manifold loose / cracked Check & tighten / replace inlet
manifold

Spark plug loose Tighten spark plug to torque

Tappets adjusted too tight Check & adjust tappets

correctly

Cylinder head bolts loose Check & tighten to torque

Cylinder head gasket damaged Check & Replace

Cylinder head warped Check & Replace

C. Compression Related
Valve spring broken or weak Check & Replace

Valve not seating properly (valve Check & Replace

bent, worn, carbon accumulation
on the seating surface.)

Excessive Carbon in combustion Check & Clean

chamber

Piston ring bad (worn, weak, Check & Replace

broken, or sticking)

Piston rings clearance excessive Check & Replace

Cylinder, piston worn Check & Replace

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6. EXHAUST SMOKE EXCESS
Symptom Probable Cause Remedy
Adulterated / Bad fuel Clean fuel tank
Fill with fresh fuel

Spark plug Electrode gap too less Check and correct electrode gap

A. Black smoke Spark plug wrong specifications Replace with correct spark plug

Air Filter element clogged Check & Clean

Pulse air valve pipe connections Check & correct

loose / cracked

Ignition coil defective Check & replace

Adulterated / Bad fuel Clean fuel tank.

B. Brown smoke Fill with fresh fuel

Air filter box poorly sealed / Check & correct

element partially clogged

Engine oil level too high Check & Maintain Oil level as
Recommended

Valve stem seal damaged Check & correct

C. Bluish / White smoke Excess clearance between valve Check & correct
stem & guide

Oil scrapper ring worn out Check & correct

Cylinder barrel / piston clearance Check & replace

high

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7. ENGINE HEAT EXCESSIVE
Attribute Probable Cause Remedy
Prolonged driving in low gear at High Ride in appropriate gear as
speeds / High gear at Low speeds required by traffic conditions
Engine in Idling RPM for prolonged Switch off Engine if required to
periods be in standstill traffic for more
A. Driving / traffic related than 2 minutes.
Vehicle in standstill with gear engaged and Shift to neutral & release clutch
clutch depressed for prolonged periods
Engine RPM high when vehicle at Allow engine to run in idling
standstill position RPM when in neutral
Riding in traffic with brakes partially Release both brakes and drive
engaged for prolonged periods at appropriate speeds
Spark plug electrode gap too less/excessive Check and correct electrode gap
Spark plug wrong specifications Replace with correct spark plug
Spark plug insulator cracked Check & replace
B. Ignition Related Suppressor cap/ H T lead loose Check & correct as required
Suppressor cap/ H T lead defective Check & correct as required
Ignition coil defective Check & Replace
Pulsar coil / Magneto defective Check & replace
Adulterated / Bad fuel Clean fuel tank
C. Fuel / Induction related Fill with fresh fuel
Air filter dirty / clogged Check & clean / replace
Spark plug loose Tighten spark plug to torque
Tappets adjusted too tight Check & adjust tappets correctly
D. Compression Related
Excessive Carbon in combustion chamber Check & Clean
Poor compression due to cyl. head gasket Check & correct
blown, Valve seating improper, Piston rings
worn out / broken, Piston/Cyl. worn out
Engine oil less viscous / wrong Check & correct
specification / level too low
E. Others Oil cooler fins dirty / blocked Check & clean oil cooler fins
Clutch slipping Check & correct
Front / Rear brakes jammed Check & correct
Engine oil pressure less Check & correct
Silencer choked Check & clean

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8. ENGINE NOISY
Attribute Probable Cause Remedy
Prolonged driving in low gear at High Ride in appropriate gear as
speeds / High gear at Low speeds required by traffic conditions
Excessive Engine heat Check & correct
Adulterated / Bad fuel Clean fuel tank.
Fill fresh fuel
A. Knocking noise Incorrect plug gap. Wrong spec spark plug Check & correct gap
Excessive carbon in combustion chamber Check & correct
Pulse air valve pipe connections loose / Check & correct
cracked
Exhaust pipe & cylinder head joint not Check & tighten exhaust flange
sealed correctly nuts / replace gasket
Engine oil less viscous/wrong specification Check & correct
/ level too low
B. Lubrication related Oil filter element blocked Replace filter element
Oil pressure low Check & correct
Tappets clearance excessive Check & adjust tappets
correctly
Camshaft sticky rotation Check & correct
C. Top End noise Cam lobes in camshaft uneven wear Check & replace
Cylinder head gasket blown Check & replace
Valve spring broken / weak Check & replace
Valve stem squeaky noise Replace stem seals
Valve stem to guide clearance high Check & replace
Piston rings broken Check & replace
Cylinder / Piston scored Check & replace. Check air filter
/ housing also for damages
D. Cylinder barrel / central Excess clearance between piston / barrel Check & replace
(Piston slap)
portion noise Cam chain pads worn out Check & replace
Auto chain tensioner jammed Check & replace
Excessive clearance between Cam chain / Check & replace
sprockets
Connecting rod small end / piston pin Check & replace
clearance excess
Connecting rod bent Check & replace crankshaft
Excess clearance between connecting rod Check & replace crankshaft
E. Bottom end noise big end / crank pin
Crankshaft / balancer shaft support Check & replace
bearings worn
Crankshaft run out excessive Check & replace
Balancer shaft / crankshaft gears backlash Check & correct
Clutch housing/friction plate clearance Check & replace
excessive
F. Transmission noise Clutch housing gear / crank gear backlash Replace matched gears
Drive / counter gears backlash Check & replace
Drive / Countershaft bearings worn out Check & replace
Gears / bushes seized in drive /counter shaft Check & replace

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9. GEAR SHIFTING HARD / SLIPS
Attribute Probable Cause Remedy
Routing improper Check & correct
Strapped too tight to frame Check & correct
A. Clutch cable related
Inner cable sticky Check & replace
Inner/outer cable damaged Check & replace
Free play excess Correct free play to 2-3mm
Oil less / more viscous. Wrong specification Check & correct
B. Oil related
Oil level too high / too low Check & correct
Gear lever position incorrect Check & correct
Shift lever sticky / jammed on pivot pin Check, clean & lubricate pivot pin
C. Shift lever / linkage / Gear shift linkage ball joint stuck/worn out Check & correct
shifting Mechanism Return spring weak / broken Check & replace
related Indexing pawl pins worn out Check & replace
Shift forks sticky in pin / selector drum Check & correct
Shift forks / pins worn out Check & replace
Selector drum grooves worn out Check & replace
Clutch pad sticky / worn out Check & replace
Clutch plates movement sticky Check & correct
D. Clutch assembly related Springs weak / broken Check & replace
Friction plates worn out / burnt Check & replace
Steel plates warped Check & replace
No end float of clutch assembly in shaft Check & correct
Shift forks sticky in pin / selector drum Check & correct

E. Gears does not engage Selector drum rotation sticky Check & correct
Sliding gear movement sticky in shaft Check & correct
Gears / bushes partially seized in shaft Check & correct
Shift forks / pins worn out Check & replace
Selector drum grooves worn out Check & replace
F. Gears overshifts Sliding Gear dogs worn out Check & replace
Drive shaft/counter shaft splines worn out Check & replace
Drive / counter shaft bearings wornout Check & replace

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SECTION 13.2 - EMS TROUBLE SHOOTING

ISSUE DESCRIPTION EMS COMPONENT CHECK POINTS

ECU Check for P codes/blink pattern as mentioned in previous slide
for ECU internal error or any other internal issues.
Fuel Injector, * Check for Connector loose fitment, terminal back out or wire
cut etc.
Roll Over Sensor * Check for supply voltage, battery voltage etc.
* Check for Connector loose fitment, terminal back out or wire
cut etc.
* Check for supply voltage, battery voltage etc.
Vehicle not starting Ignition Coil * Check for harness continuity.
* Check for suppressor cap loose connection
* Check for sparkplug contamination
* Check for Connector loose fitment, terminal back out or wire
Crank Position Sensor cut etc.
* Check for crank shaft position sensor resistance.
Flywheel Magneto Assy * Check for stator short circuit.
* Check for connector loose fitment.
DTC History not ECU Clear DTC using only scan tool, do not re-set ECU by test pin
able to clear method

Fuel pump ECU ECU internal short, replace ECU

Continuous ON
Fuel Pump Fuel Pump Check for Connector loose fitment, terminal back out or wire
Not working cut etc.
Check for supply voltage, battery voltage etc.
Fuel pressure loss/ Fuel Pump Check for leakage near connectors
no fuel supply Check for clogged filter
Fuel pump short Pulse Fuel Pump Fuel pump Primes for 2 Sec, If priming cycle is less than 2 sec
check for Ignition coil Connector.
Fuel dripping through Fuel Pump Check for Pressure Lock in tank, if pressure lock is not there
Pump Nipple replace the pump
If Pressure Lock is there check for Tank Cap and EVAP Purge
valve.

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ISSUE DESCRIPTION EMS COMPONENT CHECK POINTS
Poor Feeling of Fuel Injector Check for Injector Block
acceleration, Check if Pressure is built by pump,
hesitation, Vehicle Check for any Kinks in Fuel hose.
Could not reach Max
Speed
Vehicle mis-firing/ Crank Position Sensor Check for crankshaft position sensor mounting
tachometer fluctuation  Throttle Position Check for supply voltage, battery voltage etc.
Sensor
Low battery Flywheel * Check for stator short circuit.
Magneto Assy * Check for connector loose fitment.
Heater Circuit Failure HEGO Sensor Check for Connector loose fitment, terminal back out or wire
cut etc.
Sensor Circuit Failure HEGO Sensor Check for Connector loose fitment, terminal back out or wire
cut etc.
Engine Oil * Check Connectors for loose pin
Temperature (TE) * If the issue still persists Replace Sensor
Sensor
TA Sensor Check for Connector loose fitment, terminal back out or wire
cut etc.
Sensor Circuit MAP Sensor Check for Connector loose fitment, terminal back out or wire
Malfunction cut etc.
EXAI Sensor * Check for Connector loose fitment, terminal back out or wire
cut etc.
* If terminals are in good condition replace Solenoid.
Throttle Position * Check for Connector loose fitment, terminal back out or wire
Sensor cut etc.
* Check for Supply Voltage
MIL distance not Vehicle Speed Sensor * Check for Connector loose fitment, terminal back out or wire
showing in diagnostic cut etc.
tool * Check for Supply Voltage

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 Royal Enfield Support : 1800-2100-007
Email : [email protected]
Twitter : @RoyalEnfieldSupport
Web : www.royalenfield.com

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